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BMW 1997 5251 Sedan, Service Manual

The BMW 1997 525i Sedan Service Manual is a valuable resource for owners looking to maintain their vehicle's performance. This manual covers essential repair and maintenance information to keep your BMW running smoothly. Download your free manual from manualshive.com to ensure your car stays in top condition.

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Summary of Contents for 1997 5251 Sedan

Page 1: ...Service Manua 5251 5281 530i 540i Sedan Sport Wagon 1997 1998 1999 2000 2001 2002 www bmwclub pro BMW PRO FORUM...

Page 2: ...in or contribute in some way to an occurrence which might cause you injuly damage your car or result in an unsafe repair If you have doubts for these or other reasons about your ability to pelformsaf...

Page 3: ...haustSystem 240 Automatic Transmission 250 Gearshift Linkage 260 Driveshaft Suspension 300 Suspension Steering and 330 Rear Suspension Brakes General 331 Final Drive Steering and N o Front Suspension...

Page 4: ...Corvctlc Illustralcd Encyclopedia TornBeifurli ISBN 0 8376 0928 3 Racc Car Aerodynamics losupli Kntz ISBN 0 8376 014 8 Road Track Illustrated Automotive Dictionary JoltriDilrkl ISBN 0 8376 11143 6 Sc...

Page 5: ...ase also read the Important Safety Notice on the copyright page at the beginning of this book Prior to starting a repair procedure read the procedure 001 General Warnings and Cautions and the warnigns...

Page 6: ......

Page 7: ...ide kills Rings bracelets and other jewelry should be removed so that they cannot cause electrical shorts get caught in running ma chinery or be crushed by heavy parts Tie long hair behind your head D...

Page 8: ...this manual are for reference only Always check with your authorized BMW deal er parts department for the latest information Before starting a job make certain that you have all the neces sary tools...

Page 9: ...ignation Examples X for 1999 Y for 2000 1for 2001 2 for 2002 etc The table below explains some of the codes in the VIN for 1997 through 2002 BMW E39 5 Series BMWs covered by this manual Sample VIN I z...

Page 10: ......

Page 11: ...fasteners O10 8 Gaskets and seals O10 9 Electrical testing O10 10 Wire repairs O10 10 Buying Parts 010 11 Genuine BMW parts O10 11 Non returnable parts O10 11 Information you need to know 0l0 12 Serv...

Page 12: ...all of thepossible hazards that may result MOW TO USE THIS MANUAL WARNING Yourcommon sense and goodjudgement are crucial to safe and successful service work Read procedures through be fore starting th...

Page 13: ...d diagnostic information Warnings cautions and notes Throughoutthis manual are many passageswith the head ings WARNING CAUTION or NOTE These very important headingshave different meanings WARNING The...

Page 14: ...eaters or other fire hazards Keep an approved fire extinguisher handy The fuel system is designed to retain pressure even when the ignition is off When worlcing with the fuelsys tem loosen the fuel li...

Page 15: ...s or just in front of the rear wheels WARNING Never work undera liftedcar unlessitis solidlysupported onjack stands that are intendedfor thatpurpose When raising the car usinga floorjack or hydraulicl...

Page 16: ...bed above Use at least two jack stands to support car Usejack stands designed for the purpose of supporting a car See Tools WARNING Ajaclc is a temporarylifting deviceandshould not be used alone to su...

Page 17: ...priorto assembly commerciallyavailable aerosol cans of parts cleaner or brake cleaner are handyto use and the cleaner will evaporatecompletely WARNING Mostsolvents usedfor cleaningpartsare highlyflam...

Page 18: ...re are several fasteners tighten them in a se NOTE Metric bolt classes or grades are rnarlcedon the bolt head Donotconfuse wrenchsize withbolt diameter Fora listing of the common wrenches usedon vario...

Page 19: ...ing flex ble lip seals are usedto keep the lubri cating 011 or grease from leaking out pastthe rotatlng shaft Seals should never be reusedonce they have been removed When rernovlng a seal be careful n...

Page 20: ...or Car body otherwise damaged cut off the end and remove enough insu ground i Battery lation to complete the repair if the wire istoo short splice ina BOZLiEL new piece of wire of the same size and m...

Page 21: ...ops makea pointof usinggenu ine BMW parts eventhough they may at times be moreex pensivethan parts from other sources They know the value of doingthejob rightwithihe right parts Partsfrom other source...

Page 22: ...o your car The label on the driver sdoor below the door latch will specify the monthand year that the car was built Vehicle IdentificationNumber VIN This is a combination of letters and numbersthat id...

Page 23: ...k at first use to very expensive and well made tools for the professional The besttools for most do it yourself BMW owners lie somewhere in between Many reputable tool manufacturers offer goodquality...

Page 24: ...ad Wrenches 4 Wrenches come in different styles including open end 12 point box end 6 point box end and flare nut The basic open end wrench is the most widely used but grips on only two sides The box...

Page 25: ...et for sparlt plugs includes a rubber in sert to both protect the spark plugfrom damage and grip itfor easier removal Pliers There are many types of pliers including snap ring needle nose adjustable j...

Page 26: ...The best ones are made of heavy materialfor strength have a wide base for sta bility and are equipped to positively lock in their raised posi tion Get the best ones available Compared to a wrench of t...

Page 27: ...50 Nm 110ft lb BOIBFNG has adequate capacity for most of the repairs covered inthis manual For recommendedtorque values of 10Nm orbelow the English system equivalent is given in inch pounds in lb Thes...

Page 28: ...y seen by other drivers Avoid stoppingjust over the crest of a hill WARNING Ifa tiregoesflat while driving pullwelloffthe road Changing a tire on a busy slreet or liigliwayis very dangerous Ifnec essa...

Page 29: ...one minute before boosting the batterya second time crisscross pattern Torque wheel nuts when installingwheel Check inflation pressure of spare tire Tightening torque Wheel to wheel hub 120 Nm 89 ft i...

Page 30: ...towing eye can be screwed into the front or rear bumper 4 Install towing eye into threaded hole Standard transmission Do not tow with rear wheels on ground unless absolutely necessary Automatic trans...

Page 31: ...e belt s BMW engine oil one or two quarts BMW engine coolant 1 gallon of premixed 50150 BMW anti freeze and water Fuse assortment 7 5A IOA 15A 20A 30A 50A Radiator hoses upper and lower Spare parts ki...

Page 32: ......

Page 33: ...checking cleaning and replacing 020 22 Brake fluid replacing 020 24 Brake pad1rotor wear checking 020 24 Brake system inspecting 020 25 Parking brake checking 020 25 Clutch fluid checking 020 26 Diffe...

Page 34: ...tainingfullprotection under BMW s new car warranty coverage If in doubt about the terms and conditions ofyour car s warranty an autho rized BMW dealer shouldbe able to explain them to you Special tool...

Page 35: ...fuel This volume varies between models dependent on vehicle and engine size The Sil control unit receives a signal from the engine control module ECM when the vehi cle is in use As 20 of the programm...

Page 36: ...ool com http www asttool com BaumTools Unlimited Inc P O Box 5867 Sarasota FL 34277 5867 800 848 6657 sales baumtools com http www baumtools com Peake Research Automotive Products Division P O Box 287...

Page 37: ...lnspection I lnspection II The Service Interval Indicator SII signalsthe needfor main tenance and inspection There are two sets of inspectionre quirements alternating throughout a car s maintenance hi...

Page 38: ...manual where additional information can be found Table a Oil Service I I I I IAdditional Newparts Tools Required requrred Under car maintenance 1 I I I I I I I I Engine compartment maintenance Check...

Page 39: ...Grease wheel centering hubs Checlt thickness of parking brake linings only when replacing rear brake shoes Checit operation of pariting brake and adjust as necessary Checlt front control arm bushings...

Page 40: ...asher jets and adjust if necessary covers obvious damage or attachment o s or accessories Road test Check braking performance steering heating and air conditioner operation Check manual transmission a...

Page 41: ...years time interval begins from vehicle production date Replace oxygen sensor every 160 000 itm 100 000 miles 020 FLUIDAND LUBRICANT SPECIFICATIONS I Oxygen sensor service x Spark plugs M52 1M62 engi...

Page 42: ...1 I liters 1 2 US quarts BMW part no 83 22 408 942 I quarts Getrao S6S 420G 11 9 liters 2 0 US Table f Automatic transmission fluid ATF Lifetime fluid drain and refill Additional fluid required when i...

Page 43: ...lgh performance DOT 4 Approximate capacity 9 9 liter 10 5 US qt 11 4 liter 12 0 US qt With the introduction of synthetic oil and extended oil change intervals a new oil filterwith improved filter pape...

Page 44: ...wed remember that an authorized BMW dealer has the latest information on factory recommended maintenance CAUTIOIG In the case of cars that accumulate very low mileage per yea BMW recommends that the e...

Page 45: ...makesure the technician hand starts and torques the engine oildrain plug using hand tools Power tools can strip the threads of the plug and the oilpan Run enginefor afew minutesto warm engine oil Shut...

Page 46: ...t oil pressure warning light immediately goes out Allow engine to runfora few minutes to circulate new oil then check for leaks at drain plug and oil filter Stop engine and re check oil level The sect...

Page 47: ...hat is a50 150 mixtureof distilled water and ethGene glycol based antifreeze Routinecooling system maintenanceconsists of maintaining thecoolant levelandinspectinghoses Becausethecoolant s anticorrosi...

Page 48: ...ine belts The outer belt turns the NC compressor 0 The inner longer beltturns the alternator generator cool ant pump and power steering pump Inspectdrive belts with the engine off Ifthe belt shows sig...

Page 49: ...wise and remove belt Some models have a dust cover over belt tensioner release lug which must be pried off prior to removing belt 4 6 cylinder engine with spring loaded belt tensioners Use long handle...

Page 50: ...er style tensioner is similar 4V 8engine tensioner Loosen fasteners A to relieve belt tension Remove drive belt 4When reinstallingbelt check that it is correctly positionedon belt pulleys With bolts B...

Page 51: ...electronically adaptive and not adjustable See 130 Fuel Injectionfor more informa tion Catalytic converter and oxygen sensors OBD II enhanced emission standards requirethe engine control module ECM to...

Page 52: ...luid reservoir Park car on level ground with engine off Level is correct if it is between MlN and MAX marks on dipstick If level is below MlN mark add fluid to reservoir to bring level up Hand tighten...

Page 53: ...intake manifold 6 cylinder engine Remove oil filler cap Remove plastic trim covers arrows Remove cover hold down bolts Remove coil cover s 6 cylinder engine Temporarily reinstall oil filler cap to kee...

Page 54: ...ace the microfilter unclip the wire fastener and remove the cover Lift out the filter and replace Left side shown right is similar Replace cover and clip wire fastener to retain cover Battery checking...

Page 55: ...NOTE The original equipment battery in E39 models is mainte nance free The original electrolyte will normally last the entire service life of the battery undermoderate climatecon ditions Battery elect...

Page 56: ...cing Brakefluid absorbs moistureeasily and moistureinthe fluid affects bralte performanceand reliability This is why BMW strictly recommends replacingthe braltefluid everytwo years When replacingor ad...

Page 57: ...Check that bralte hoses are correctly routedto avoidchafing or Itinking lnspect unions and brake calipers for signs of fluid leaks lnspect rigid lines for corrosion dents or other damage Inspectflexib...

Page 58: ...lutch operatingsystem Differential oil level checking The E39 differentialisfilled with lifetimeoil that ordinarily does not needto be changed BMW recommendsusingonly a speciallyformulatedsynthetic ge...

Page 59: ...duled maintenance of the exhaust system is limited to inspection Check to see that all the hangers arrow are in place and properly supporting the system and that the system does not strike the body Ch...

Page 60: ...ectionsbefore removingthem After assembly check filter connectionscarefully for I I lealcs before installing cover NOTE Additionalinformarionabout the fuel filler assembly is in 160 Fuel Tank and Fuel...

Page 61: ...uring season al temperature changes Correct inflationpressurescan be foundon the driver s door pillar and inthe owner s manual Notethat tire pressuresshould be higherwhen the car is more heavily loade...

Page 62: ...eenaroundthe driveshaft mountingflangeandat the bottomof the bellhousing NOTE Formore informationon identifyingoil leaks and their causes see 230 Manual Transmission and210 Clutch Transmission fluid c...

Page 63: ...unlight Ifthe engine hood is warm allow itto cool Beads of water not only leave spots when dried rapidlybythe sunor heatfromtheengine butalso can act as small magnifying glasses and burnspots into the...

Page 64: ...re tractor mechanisms should beinspected See720Seat Belts for seat belt inspection information Speciai cieaning Tarspots can be removedwith a bug and tar remover Never use gasoline lterosene nail pol...

Page 65: ...epress retaining tab arrow and slide blade out of arm I Checlc tension spring that forces wiper against glass Re place wiper arm if spring tension is weak Drops that remain behind after wiping are cau...

Page 66: ......

Page 67: ...100 Engine General General I 00 2 Driveability Troubleshooting 100 4 Engine identifying features I 00 3 System voltage 100 5 Main grounds 100 5...

Page 68: ...ferto the appropriate repair group 110 Engine Removal and Installation 0 113 Cylinder Head Removal and Installation 116 Cylinder Head and Valvetrain 0 117 Camshaft Timing Chain 119 Lubrication System...

Page 69: ...iming 4 The M52 TU engine MY99 00 5281 and the M54 engines MY01 02 525il530i are fitted with double VANOS The en gine blocits are constructed of aluminum alloy with cast iron cylinder sleeves 4 The do...

Page 70: ...e connecting the throttle pedal to the throttle housing in these cars Compact water cooled generator alternator E39 vehicles are equipped with sophisticated self diagnostic engine management systems T...

Page 71: ...osion inthe wiring harness and connec tors are not uncommon Checkthe batteryterminals forcorro sion or loose cable connections See 121Battery Starter Alternator for additional information If a battery...

Page 72: ...d component locations 4 Ground for engine management system in right rear of en gine compartment on E box bulkhead arrow 6 cylinder models Grounds for ignition coils arrows 4 V 8 models Grounds for ig...

Page 73: ...110 Engine Removal and installation General I10 2 Engine Removal and Installation Special tools I 10 2 V 8 models 110 16 Engine Removal and Installation 6 cylinder I 10 3...

Page 74: ...edures re quiredduring engine removal refer to the following repair groups 020 Maintenance 0 121 Battery Alternator Starter 170 Radiator and Cooling System 180 Exhaust System 4 230 Manual Transmission...

Page 75: ...opriaterepair group in this manual or an authorized BMW dealer for more information on fault codes NOTE Engine removal procedures are similar for all 6 cylinder models Whendifferences exist they are n...

Page 76: ...isconnect electrical harness from hood switch C Release spring loclt D Slide filter housing away from inner fender to remove Removal of right side ventilation duct is similar Remove rear bulkhead pane...

Page 77: ...M52 engine Oxygen sensor connectors 8 Electrical harness connector from intaltecamshaft VANOS solenoid valve C M52 engine Disconnect electrical harness connectors at throttle valve position switch D A...

Page 78: ...uisher handy Before disconnectingfuel hoses wrapa cloth around fuel hoses to absorb any leaking fuel Catch and dispose of escapedfuel Plug all open fuel lines Alwavs unscrew the Fuel tank cao to relea...

Page 79: ...redisconnectingfuelhoses wrapa clotharound fuelhoses to absorb any leaking fuel PlugalloDen fuellines M52 engine Remove throttle valve and ASC throttle assemblies Disconnect ASC throttle cable A Remov...

Page 80: ...ws retaining wiring harness conduit to throttle body 4 M52TU M54 engine Working at throttle housing rotate har ness plug arrow counterclockwise and remove 4 M52 TU M54 engine Disconnect electrical har...

Page 81: ...ectrical harnessconnector underside of intake manifold near throttle body M52TU M54engine Resonancevalve electrical harness connector M52 engine Fuel tank vent line and harness Working underneath car...

Page 82: ...ust enough to remove positive cables from starter motor terminal 50 arrow Remove intake manifoldfrom cylinder head while carefully checking for electrical connections tie wraps and hoses CAUTION Stuff...

Page 83: ...drain plug located on exhaust side of cylinder 2 of engine block arrow NOTE Drainplug for M52 TUandM54 engineshown Plugfor M52 locatedbetween cylinders 4 and5 Drain radiator by removing plastic drain...

Page 84: ...tandard band clamps On vehicles equipped with mechanicalcooling fan Remove belt driven cooling fan and radiator as described in 170 Ra diator and Cooling System CAUTION 32 mm radiatorfan mountingnutha...

Page 85: ...om radiator re movebracketsholdinglines toside of engine andstore lines ina clean environment Remove power steering pump If necessary remove steering pump pulley Remove front and rear pump mounting bo...

Page 86: ...embled correctly Do notinterchangeconnectors 4 Remove chassis ground strap arrow at right engine rnount ing pedestal 4 Install an engine lifting device BMW 11 0 000 or equivalent to the front and rear...

Page 87: ...l other fluid levels See 020 Maintenance Refill and bleed cooling system See 170 Radiator and Cooling System CAUTION When reattaching throttleassemblyharnessconnectoc con nector is fuNytightened when...

Page 88: ...ses before removing them Do not reuse gaskets O rings or seals during reassembly WARNING Due to risk ofpersonalinjury be sure the engine is cold be fore beginning the removalprocedure Disconnect negat...

Page 89: ...orting clip El Unlock panel retainers arrows Lifl out panel Separate engine wiring harness arrow from electrical box at right side of engine compartment Remove E box cover Disconnect electrical harnes...

Page 90: ...les of fuel line connections a slngle use clamp a locking fitting that uses special tool 16 7 050 to re lease and a quiclc release sleeve arrows that disconnects the line when depressed WARNING Fuel I...

Page 91: ...ssconnector A and removeand plugfuel tank vent valve vacuum line 0 Raise car and support in a safe manner CAUTION Male sure the carisstable and wellsupportedat aNtimes Useaprofessionalautomotivelifior...

Page 92: ...ater cooled alternator Remove exhaust system and transmission See 180 Ex haust System and 230 Manual Transmission or 240 Auto matic Transmission Working at front of engine Remove upper and lower hoses...

Page 93: ...reverse of removal Replace all gaskets O rings and seals V 8 engine mounts have two sets of mounting holes E39 cars use front most mounting holes On cars with automatic transmission use new O rings a...

Page 94: ...22 Nm 17 ft lb Coolant drain plug to cylinder blocic M14 25 Nm 18 ft lb Engine mount to engine bracket or 47 Nm 35 ft lb subframe M10 Exhaust flange nuts 8mm 25 Nm 18 ff ib Radiator cooling fan to coo...

Page 95: ...llation M52 TU and M54 Engines 113 22 Cylinder head removing M52 TU and M54 engines I 13 22 Cylinder head installing M52 TU and M54 engine I 13 39 Double VANOS Timing Chain Components 113 46 Double VA...

Page 96: ...or the M62V 8 are also included butthe proceduresforthe M62TU V 8 with VANOS are not provided For cylinder head and valvetrain reconditioning information see 116 Cylinder Head and Valvetrain For speci...

Page 97: ...or cylinder head bolts Tool No BMW 11 2 250 4 Crankshaft loclting tool Tool No BMW 11 2 300 4 Camshaft lockingtool set 6 cylinder I Tool No BMW 11 3 240 Timing chain adjustable tension setup tool 6 cy...

Page 98: ...11 2 441111 2 443111 2 444 4 Timing chain adjustable tension setup tool V 8 Tool No BMW 11 3 390 Secondary timing chain tensioner loclting pin V 8 Tool No BMW 11 3 310 4 Hydraulic lifter securing plug...

Page 99: ...ssion checking A compressiongauge is neededto makea compressiontest For accuratetest the batteryand starter must be capable of cranking the engine at least 300 rpm and the engine should be at normalop...

Page 100: ...ng straps I CAUTION I nition system components I Remove coils Remove spark plugs from all cylinders NOTE Check the spark plugs for oil deposits that may indicate poor cylinder sealing then set them as...

Page 101: ...ions reinstall spark plugs and ignition coils NOTE Usedspark plugs should be reinstalledin the same cylinder from which they were removed Tightening torque Spark plug to cylinder head 25 Nm 18ft lb la...

Page 102: ...test to confirm low compression Y L N D E R HEAD REMOVAL AND NSTALLATION M52 ENGINE WARNING Due to rislc ofpersonalfnjur be sure the engine is coldbe fore beginningthe removalprocedure Cylinder head r...

Page 103: ...e 4 retaining screws 6 Lift out panel Remove complete air filter housing Loosen intake duct hose clamp A at throttle assembly Loosen clamp and remove idle control hose from ntake duct 6 and disconnect...

Page 104: ...back through feed line using a brief burst of compressedair max imum of 3 bar or 43 5 psi WARNING Fuelinfuellineis underpressure approx 3 5baror 45 75psi andmay be expelled Do notsmoke or work near he...

Page 105: ...ectrical harness connector underside of intake manifold near throttle body Fuel tank vent line and electrical harness at canister vent valve Remove lower intake manifold supports arrows Disconnect coo...

Page 106: ...ition coils Disconnect ignition coil harness connectors Remove coil mounting fasteners Remove coils Remove ground straps NOTE Make note of ground wire at mounting studs arrangement during removal Remo...

Page 107: ...olt in direction of rotation clocltwise when viewed from front of engine until camshaft lobes for cylinder 1 face each other dotted lines and arrows on camshaft sprocltets face up Set engine to TDC by...

Page 108: ...xoncamshaft whenloos eninqor tiqhteninqsprocl etmountingfasteners r Pressdown onsecondarychaintensioner and lockinto place using BMW special tool 11 3 292 or a similar size pin NOTE Some tensionersmay...

Page 109: ...tensioner arrow WARNING Remove tensionerslowly it is underspringpressure I Working at the intake side of cylinder 1 Detach electrical harness connectorfor camshaft position sensor and remove sensor De...

Page 110: ...C The tool holds the camshaftsparallel to each other and NOTE Do not remove the sprocl etsfrom the chain unless these parts are being replaced Wire tie each sprocket to the chain to Iceep the sproclef...

Page 111: ...result ing in open valves Camshaft installationwaiting times 68 F 20 C and higher 4 minutes 50 68 F 10 20 C 11 minutes 32 50 F 0 10 C 30 minutes Clean cylinder head and gasket surfaces of cylinder blo...

Page 112: ...the cylinder head Make sure the cranksha which had been rotated approx imately 30 opposite the direction of engine rotation is still in that position before lowering the cylinder head into posi tion L...

Page 113: ...chain sprocl ets Sprockets that have worn or missing teeth should be replaced If any of the sprocketsare being replaced due to wear the chain should also be replaced Ifthe crankshaft sproclet requir...

Page 114: ...ckets and chain as an assembly so that arrows on sprockets are pointingup Center mounting holes in sprockets to bolt holes in camshafts 4 lnstall thrust washers and diaphragm spring to intake cam spro...

Page 115: ...sealant at corners 6 of half moon cutouts Seat gasket and seal corners in front of cylinder head at VANOS unit Installation of remaining parts is reverse of removal noting the following Reinstall elec...

Page 116: ...beforebeginningthis procedure Disconnect negative cable from battery CAUTION Prior to disconnectingthe battery readthe batterydiscon nectioncautionsin 001 General Cautions and Warnings 4 Remove left...

Page 117: ...y cable and remove intake rnani fold cover Remove protective cover from positive jumper post Loosen and remove battery lead mounting nut A Remove lead and push down through intake manifold Remove trim...

Page 118: ...Using a tire chuck blow fuel back through feed line using a brief burst of compressed air maximum of 3 bar or 43 5 psi WARNING Fuelis underpressure approx 3 5baror45 75psi and may be expelled Do not...

Page 119: ...ters or other fire hazards Keep a fire extinguisher handy Before disconnecting fuel hoses wrapa clotharound fuel hoses toabsorbany leaking fuel Plugall open fuel lines NOJE BMW uses various styles of...

Page 120: ...at fuel tank venting valve A and vent hose at quick disconnect fitting arrow Working under intake manifold disconnect the following Engine oil dipstick tube support Oil separator return line from dip...

Page 121: ...line support bracket at rear of intake mani fold Guide fuel line s out of rear of engine compartment while lifting fuel rail out 4 Remove intake manifold mountino hardware arrows I from falling into t...

Page 122: ...ntisingested NOTE Catch and dispose of drained coolant according to local state and federal laws 4Remove thermostat housing Disconnect electrical harness connector at thermostat housing Removehosesfro...

Page 123: ...ors Remove coil mountingfasteners Remove coils Remove ground straps CAUTIOI C Notelocationofallgroundwires Failureto reinstallgrounds canresultinpermanentdamageto enginecontrolmoduleor ignitionsystem...

Page 124: ...drive belts 4 Cover oil hole arrow in VANOS unit with shop towel to cap ture oil which will spray when compressed air is applied Connect compressed air line to air fitting Apply air pressure set to 2...

Page 125: ...shaft in TDC po sition with BMW special tool l l 2 300 arrow 4 Unscrew and remove two cylinder head cover studs arrows at rear of cylinder head 4 Secure camshafts in TDC position using BMW special too...

Page 126: ...eady Do not allow oil to run onto drive belts Pull sealing caps straight out of VANOS unit using short nee dle nose pliers NOTE Additional oilmay drain from VANOS unit Remove set screws left hand thre...

Page 127: ...ll quantity of oil Place shop towel to catch oil as unit is removed or tilted CAUTION If the VANOSadjustmentunit is replaced or if operationsare completed that may change the timing of the camshafts t...

Page 128: ...exhaust camshaft impulse wheel mounting nuts arrows Remove impulse wheel A 4 Remove spring plate A 4 Remove intake camshaft sprocltet mounting nuts arrows and remove spring plate labelled FRONT Remove...

Page 129: ...er A and splined shafl B CAUTION Splinedshaftsshare the samepart numberfor bothintake andexhaustcamshafts Usedsplinedshafts mustbe rein stalledin their originalpositions Remove exhaust camshaft spline...

Page 130: ...ove sprocket mounting studs arrows from exhaust camshaft Lift primary chain sprocltet off exhaust camshaft sprocket from chain 4 Place timing chain on end of exhaust camshaft Remove 4 Spline retaining...

Page 131: ...30 CAUTION By turningcrankshait3O0 pistonsare movedawayfrom top deadcenter topreventpossible valve interferencetopistons during camshaftservicing Remove camshaft loclting tools BMW special tool set 11...

Page 132: ...mshaft 4 Secure hydraulic lifters in lifter bores using BMW speclaltool 11 3 250 or remove lifters using a magnetic pick up tool With lifters secure or removed lift out camshaft bearing car riers from...

Page 133: ...an cylinder head and gasket surfaces of cylinder bloclc and all timing chain covers CAUTION Removeforeignmatterand liquidfromboltholes Trappedoil or coolant in bolt holes can cause damage to blocl CAU...

Page 134: ...tion from TDC is still in thatposition before lowering the cylinderhead intoposition All pistons must be out of TDCposition to pre vent valve pistoninterference when the camshafts are in stalled Light...

Page 135: ...camshaft position sensor arrow 4 Install lower secondary chain guide Tighten tom bolts to specifications The bolt on the intake camshaft side is long and extends into the engine block 4 Install and t...

Page 136: ...ows on hydraulic lifter bores for signs of wear 4 Center camshaft carrier with hydraulic lifters on pins ar rows at bearing positions 2 and 7 Note markson carriers E for intakeside and A for exhaust s...

Page 137: ...all and torque nuts on intake camshaft bearing caps Tightening torque Camshaft bearing cap to cylinder head M7 14 Nm 10 ft lb Release tension on eccentric shaft and remove BMW special tools 11 3 26012...

Page 138: ...and Installation 4 Secure camshafts in TDC position using BMW special tool set 11 3 240 4 In necessary turn camshaft slightly so that special tools are squarely seated on cylinder head 4 Lift timing...

Page 139: ...ng tension on timing chain rotate crankshaft at vibration damper from 30 before TDC in direction of rota tion clockwise until number 1cylinder is at TDC position with line between the OIT arrow on fro...

Page 140: ...ndary timing chain 9 Splined sleeve 10 Primary sprocket 11 Threaded locating stud 12 Secondary chain tensioner 13 Secondary chain lower guide 14 Sprocket mounting nut 15 Spring plate intake 16 Splined...

Page 141: ...Insert BMW special tool 114 220 into timing chain tensioner boreand bring center spindle into contact with tensioning rail Tighten until slack is removed but do not pretension timing chain NOTE BMW sp...

Page 142: ...shaft splines arrows Slide splined shaft onto exhaust camshaft Be sure that locat ingtooth of shaft fits into spline gaps of camshaft and splined sleeve arrows Push splined shaft infurther to rotate s...

Page 143: ...hain when removingfrom specialtool 116 180 Align locating tooth of splined shaft with gaps on camshaft and sprocket Slide splined shaft onto intake camshaft until approx 1 mm 0 04 in of splines arrows...

Page 144: ...Install spring plate A to exhaust camshaft Malte sure that F mark is visible NOTE If Fmark is no longer visible installspring plate as shown in inset 4 Install exhaust camshaft impulsewheel aligning p...

Page 145: ...b Preload exhaust camshaft sprrng plate by pressing on im pulse wheel while tightening mounting nuts arrows finger tight Install BMW special tool 11 6 150 VANOS setup bracket to front of cylinderhead...

Page 146: ...tools from cylinder head 4 Turn engine over twice in direction of rotation until cylinder 1 intake and exhaust camshaft lobes arrows face each other Securecrankshaft in TDC position with BMW special...

Page 147: ...gasket to front of cylinder head and install VANOS unit NOTE If VANOS controlunitisbeingreplaced besure to checkand adjust camshaft timing as described in 117 Camshaft Tim ing Chain Reinstall engine l...

Page 148: ...timing chain tensioner tool and reinstall chain tensioner Tightening torque Primary chain tensioner cylinder to cylinder head 70 Nm 52 fi ib Removeflywheel locking tool from transmission bell housing...

Page 149: ...anifold bolt M6 8 Mounting bracket to cylinder block nut MIO tighten to 47 Nm 33 fi lb Intake manifold installation is reverse of removal noting the following Use new fuel injector seals Carefully che...

Page 150: ...ead 25 Nm 18 ft lb CYLINDER MEAD REMOVAL AND INSTALLATION M62 ENGINE This procedure covers cylinder headremoval and installation for the M62 V 8 engine Procedures forthe M62 TU VANOS engine are not co...

Page 151: ...strap early models not shown Release spring lock B Rotate duct inward arrow to remove Disconnect electrical harness from hood light switch C Release locking clip and removeventilation housing cover D...

Page 152: ...ignition coil cover trim caps covers from lefl and right sides remove fasteners and Disconnect throttle cables from throttle shafl A and remove cables from support bracket B Disconnect cable fromjump...

Page 153: ...sensors A Thermostat 6 Throttle position sensor and idle valve C Camshaft position sensor D Ignition coils E Remove mounting nuts arrows from wiring harness ducts 4 Release fuel injector connectors by...

Page 154: ...ION Fuel may be expelled under pressure Do not smoke or work near heaters or other fire hazards Keep a fire exfin guisher handy Before disconnecting fuel hoses wrap a cloth around fuel hoses to absorb...

Page 155: ...rain engine coolant then remove viscous clutch cooling fan See 170 Radiator and Cooling System WARNING Use extreme cautionwhen draininganddisposfngofeng ne coolant Coolantispoisonousandlethalto humans...

Page 156: ...gerside front cylinder is in TDC overlap position arrow NOJE Numberone cylinder isat valveoverlap whenboththe intake andexhaust valves are starting to open camshaft lobes fac ing down 4 Working at rig...

Page 157: ...lobes for number one cylinder should be in position shown arrows Working at right cylinder head passengers side loosen re maining sprocltet fasteners arrows on both intake and ex haust camshafts appro...

Page 158: ...Remove fasteners from intake camshaft sprocket arrows on left cylinder head Remove primary timing chain sprocket and suspend timing chain using mechanics wire to prevent chain from dropping into lower...

Page 159: ...il fasteners arrow Slide oil separator A out of cranltcase vent connecting bracket arrows CAUTIOI C When removingthe cylinderheadcarefullypress oilsepara tor outwards Loosen cylinder head bolts in seq...

Page 160: ...ugh an authorizedBMWdealerandshouldbe markedaccordingly Place new cylinder head gasket over locating sleeve on block The word OBEN or TOP arrow printed on the gasket must face up Set leflside cylinder...

Page 161: ...il return pipe at bottom of separator is correctly seated arrow NOTE Photo shows lower timing case cover removed Remove old O ring and install new O ring arrow in angle section Press oil separator int...

Page 162: ...haft locltina tool set BMW soecial tool set 11 2 440 on right cylinder head cylinders 1 4 Fit on cylinde head without gaps Install camshaft locking tool set BMW special tool set 11 2 440 on left cylin...

Page 163: ...xible shaft torque wrench I Tighten sprocket retaining bolts in the following order All bolts on left cylinder head exhaust camshaft 3 accessible bolts on right cylinder head exhaust camshaft All bolt...

Page 164: ...and mounting nuts arrows to both heads Tightening torque Oil supply line nuts 10 Nm 7 5 ft lb Remove old gasket from lefltiming cover and clean gasket surface 4 Apply Three Bond 12098 sealant to joint...

Page 165: ...Tightening torque Timing chain cover to head 10 Nrn 7 5ft lb Remove lefl cylinder head cover and BMW special tool 11 4 412 4 Reinstallcylinder head covers to left and right cylinder heads using new g...

Page 166: ...removed Tightening torques Camshaftsprocket to camshaft 15 Nm 11H lb Coolant manifoldto cylinder head 10 Nm 7 5H lb Cylinder headcover nuts 10 Nm 7 5ft lb Exhaust manifoldto head 22 Nm 17ft lb Engine...

Page 167: ...em i i I 4 Remove ignition coil fasteners and coils noting location of ground strap 1 Remove sparlc plugs i Remove oil distribution tube fasteners and remove tubes from both cylinder heads 4 Using cra...

Page 168: ...n endwrench whenever looseningor tightening camshaftsprocket fasteners Ifnecessarq grindouterside of wrenchjaws to preventdamagingcylinderhead 4 Rotate crankshaft one complete rotationto TDC overlap R...

Page 169: ...ary timing chain tensioner arrow from right cylinder head Removecamshaft positionsensor arrow chain cover on right cylinder head Remove dip stick tube support fastener from upper Remove upper timing c...

Page 170: ...d suspend timing chain using mechanics wire to prevent chain from dropping into lower housing Turn crankshaft counterclockwise until 45 mark on crank shaft is aligned with boss on front timing chain c...

Page 171: ...damage CAUTION lithe cylinderhead has been machined a special 0 3 rnm 0 011in thickergasketshouldbe installed Thethickergas ket is available throughan authorized BMW dealer and should be marked accord...

Page 172: ...open ended wrench rotate camshafts until marker bores drilled holes point upwards arrows Do not damage cylinderheadwith wrench Ifnecessary grindouterside of wrenchjaws topreventdamagingcylinder head 4...

Page 173: ...200 arrow NOTE Special tool boss locatedat the rear of upper engine oilpan Working at right cylinder head cylinder 5 8 fit primary sprocltet and chain to camshaft flange I 4 Press timing chain tensio...

Page 174: ...left intake camshaft All bolts on right intake camshaft Tightening torque Sprocitet bolts to camshaft flange 15 Nm 11 ft lb Remove camshaft and crankshaft locking tools from engine Usingcrankshaftcent...

Page 175: ...gasket and install spacing tool BMW 11 1 411 in place of gasket Install right cylinder head cover fasteners and tighten uni formly in 1 turn steps Tightening torque Cylinder headcover fasteners 10 Nm...

Page 176: ...fasteners 10 Nm 7 5It lb Install exhaust manifolds using new gaskets and fasteners See 180 Exhaust System Refilland bleedcooling system as described in 170Radiator and Cooling System Change engine oil...

Page 177: ...16 6 Valve stem oil seals 116 58 l l 6 6 Valveseats 116 59 Hydraulic lifters checking and replacing I 16 7 Valve 6 60 Camshaft andLifter Removal and Installation 116 11 Camshaft and lifter removaland...

Page 178: ...fic repair procedures referto the appropriate repair group 020Maintenance 100 Engine General 113 Cylinder Head Removal and Installation 117Camshafi Timing Chain 170 Radiator and Coo ing System Special...

Page 179: ...W 11 2 300 4Camshaft loclting tools set V 8 cyl 1 4 Tool No BMW 11 2 440 4 Camshaft locking tools set V 8 cyl 5 8 Tool No BMW 11 2 440 4 Camshaft loclting tools set 6 cylinder 1 Tool No BMW 11 3 240 4...

Page 180: ...in tensioner locking pin V 8 Tool No BMW 11 3 310 4 Adjustable primary timing chain tensioner tool V 8 Tool No BMW 11 3 390 4 Camshaft installation tool V 8 Tool No BMW 11 3 430 4 VANOS compressed air...

Page 181: ...e headfurther tested for cracks by an authorized BMW dealer or an ASE certified machinist A cracked cylinder head must be replaced NOJE When disassemblingandinspecting the cylinder head be sure to che...

Page 182: ...tion chamber facing upward Fill each combustion chamber with a thin non flammable liquid After fifteen minutes check the level of the fluid If the fluid level in any cylinder drops that cylinder is no...

Page 183: ...lifter is low Hydrauliclifter replacementrequires that the camshaft first be removed NOTE Before checking hydraulic lifters male sure engine oil is fresh andat theproperlevel Stickylifters canbe the r...

Page 184: ...ers Press down on locking pins arrows to release locks and remove top cover Pry out caps A from covers Remove fasteners and covers 4 Lift metal latch on coil harness connectors and disconnect harness...

Page 185: ...Repeat for all injectors Lift wire ducts off and set aside V 8 models disconnect battery jump start post terminal from left cylinder head cover 6 cylinder models remove oil filler cap and unclip vent...

Page 186: ...ming air being drawn inby the oilpump This may be causedby a faulty oilpump control valve O ring leaking oilpumppickup gaslcet or by oilstarvation to pump Press down on top of lifter for 10to 15second...

Page 187: ...over to cylinder iiead 10 Nrn 89 in lb fM6screws CAMSHAFT AND LIFTER REMOVAL AND NSTALLATION The camshafts can be removed with the cylinder heads mountedon the engine in the car On 6 cylinder engines...

Page 188: ...e used to remove the camshafts Be sure to read the procedure tlirough before startingajob I Allow engine to cool before beginning this procedure Disconnect negative cable from battery CAUTION Prior to...

Page 189: ...er thrust washer sprinq plate and inner thrust washer 4 Remove both camshait sprockets with secondary timing chain NOTE Keepchainandsprockets togetherasanassemblyfor easier installation Removethrust w...

Page 190: ...ICylinder Head and Valvetrain 4 Remove sensor gear arrow Remove secondary timing chain tensioner retaining bolts arrows and remove tensioner Remove timing chain guide reta ning bolts arrows and remove...

Page 191: ...qchain tensioneris undersarinaaressure 4 Remove primarytimingchain sprocketand timingchain from exhaust camshaft Remove crankshaft locking tool BMW 11 2 300 from flywheel installed during VANOS remova...

Page 192: ...any other caps Turn eccentric shaft on special tool until pressure is applied to camshaft bearing caps Remove remaining bearing cap mounting nuts Slowly releasepressureon camshaftbearingcaps by turnin...

Page 193: ...ulic lifters must be replaced into original lifter bores Camshafts and lifters installing M52Engine Lubricate camshafts camshaft carriers bearing caps hy draulic liflers frictionwashers splined shafts...

Page 194: ...fac ing each other arrows CAUTION A minimum waiting time is required for the hydraulic lifters to bleeddown after installing the camshafts into the cylinder head before bringing thepistons to TDC Whe...

Page 195: ...2 23 Nm 17ft lb Camshaft and lifter removal and installation M52 TU and M54 engine Camshafts and lifters removing M52 TU and M54 engine WARNING Allow engine fo coolbeforebeginningthis procedure Discon...

Page 196: ...loclcintoplace using BMW special tool 11 3 292 or a thin drift or pin 4 Remove exhaust camshaft impulse wheel mounting nuts arrows Remove impulse wheel A Remove spring plate A 4 Remove intake camshaft...

Page 197: ...rom exhaust camshaft and splined shaft B from intake camshaft CAUTIOf Splinedshafts share the samepart numberfor bothintake andexhaustcamshafts Usedsplinedshafts mustbe rein stalledin theiroriqinalloc...

Page 198: ...ner mounting bolts arrows and removetensioner with locking tool in place Remove primary chain sprocket mounting studs arrows on exhaust camshaft NOTE Counterhold camshafts when loosening Lifl primary...

Page 199: ...ndspline retainingscrewspreciselylocate the end splines to the camshafts Do notloosen these screws Remove locating studs arrows from intake camshaft Lift off intake camshaft thrust spacer A and impuls...

Page 200: ...o avoidcamshaft damage itmustbe removedbe fore anv other caos 4 Fit BMW special tools 11 3 260 A and 11 3270 B to cylin der head and screw long bolts aiiows into spark plug threads Tensioners will ali...

Page 201: ...carriers from cylinder head CAUTION Camshaftbearing carriersmustbereinstalledin theiroriginal locations E for intalce and A for exhaust NOTE Do not allow hydraulic lifters to fall out of camshaft carr...

Page 202: ...examine bearing bores arrows on hydraulic lifter bores for signs of wear Install camshaft carriers with hydraulic lifters into cylinder head Note marks on carriers E for intake side and A for exhaust...

Page 203: ...nuts 4 Fit BMWspecial tool 113 260 A and 11 3 270 B to cylinder head over intalte camshaft and screw long bolts arrows into spark plug threads CAUTION Do not overtightenboltsinto sparkplug holes Turn...

Page 204: ...T 3 5 mm 5 Splined shaft 6 Torx screw 7 Exhaust camshaft secondary sprocket 8 Secondary timing chain 9 Splined sleeve 10 Primary sprocket 11 Threaded stud 12 Secondary chain tensioner 13 Secondary cha...

Page 205: ...timing chain components installing M52TU M54 engine Secure camshafts in TDC position using BMW special tool set 11 3 240 4 If necessary turn camshaft so that special tools are squarely seated on cyli...

Page 206: ...ow on front pulley aligned with boss on lower timing chain cover 4 Secure crankshaft in TDC position with BMW special tool 11 2 300 arrow Slide impulse wheel on intake camshaft aligning boss with rais...

Page 207: ...center spindleinto contact with tensioning rail Tighten until slack is removed but do not pretensiontiming chain NOTE BMW special tool 11 4 220 is an adjustableprimary chain tensioner and simulates t...

Page 208: ...onfirm that gap in sleeve splines aligns with corresponding gap in carnshaft splines arrows Slide splined shaft onto exhaust camshaft so that locating tooth of shaft fits into spline gaps of camshaft...

Page 209: ...intalte sprocket splines lines up with corresponding gap in camshaft splines arrow CAUTIOI C Do notalterposition ofsprockets withrespectto chain when removinqfrom saecial tool 116 180 4 While aligning...

Page 210: ...carnshaft assembly Initiallytighten to approx 5 Nrn 44 in lb and then back off by half a turn 4 Fit thrust spacer A on exhaust camshaft 4 Install spring plate A to exhaust camshaft Make sure that F ma...

Page 211: ...tall mounting nuts ar rows finger tight 4 Pull out exhaust camshaft splined shaft to stop Press down on secondary chain tensioner and remove ten sioner lock down tool Preload primary chain Tighten adj...

Page 212: ...om face of cyiin der head Cleansealing face andkeep free of oil 4 Secure camshaft sprockets and impulse wheels Tighten mountingscrews A on exhaustcamshaft impulse wheel to approx 5 Nm 44 in lb Tighten...

Page 213: ...d This is normal Reassemble engine Other wise reset camshaft timingas describedin 1l Camshaft Timing Chain Remove BMW special tool 11 6 150 from front of cylinder head 4Clean contact edges of cylinder...

Page 214: ...cylinder head cover Use a small amount of Three Bond 8 1209 or equivalent sealing compound at corners B of half mooncutouts Seat gasket and seal corners at VANOS unit with Three Bond 1209 Tightening t...

Page 215: ...e from battery CAUTION Prior to disconnectingthe battery readthe batterydiscon nection cautionsin001 General Cautions and Warnings Dra n coolant See 170 Radiator and Cooling System Remove plastic engi...

Page 216: ...g fastener arrow Loosen hose clamp at throttle body Remove air filter housing with mass air flow sensor and duct Disconnect the following electrical harness connectors Knoclc sensors A Thermostat hous...

Page 217: ...ll injectors Lift wiring ducts off and set aside 4 Remove right and left side ignition coil mounting nuts ar rows and coils NOTE Male note of location for groundstraps arrow A Remove spark plugs Disco...

Page 218: ...DC position Lobes of camshafts for cylinder head 1 4 passengers side should point up arrows 4 Remove timing chain tensioner arrow from right side upper timing chain cover Remove secondary air injectio...

Page 219: ...left cylinder heads 4 Counterhold intalte carnshaft on right cylinder head 4 Counterhold right intalte camshaft and remove sprocltet mounting bolts arrows from right cylinder head Remove carnshaft imp...

Page 220: ...ng chain off sprocket and supend timing chain with stiff wire to prevent it from dropping into lower timing chain cover 4 Usingcranltshaft center bolt rotate engine counterclockwise to 45 before TDC p...

Page 221: ...rrows from right cylinder head Remove sprocltets with chain 4 Use BMW special tool 11 3 430 to rotate camshaft into disas sembly position 4 Loosen camshaft bearing caps nuts in correct sequence 1 10 l...

Page 222: ...for right cylinder head 1 4 is labelled A 1 4 4 Rotate camshafts so that recesses in Intake and exhaust camshafts polnt upward 30 to 40 above seal ng surface for valve cover arrows 4 Bearingcaps are m...

Page 223: ...n1 Evenly tighten down bearing cap nuts in I turn steps start ing at number 1 Tightening torque Camshaft bearing cap 14 Nm 10 ft lb BMW special tool 11 3 430 on camshaft 4 Rotate camshafts until marke...

Page 224: ...cylinderhead Ifnecessa machine open endwrench to fit Left side cyl 5 8 camshafts installing M62 engine 4Camshafts are marked for locationat rear Install camshafts into camshaft bearing saddles of cyli...

Page 225: ...ntake side and HA for the exhaust side Numbercode is for position on head with number 1 being the front bearing cap CAUTIOI C Donotmix up camshaftbearingcaps Install and evenly tighten down bearing ca...

Page 226: ...h so BMW special tools fit on cylinder heads without gaps Secure 11 2 242 11 2 446 I tool using number 8 cylinder spark plug hole CAUTION Do not damagethe cylinder head Ifnecessary machine open endwre...

Page 227: ...loclting tool Fit secondary sprockets and chain to camshafts on left cylin der head Center slots in sprocltets to threaded bores in end of camshafts arrows Insert exhaustcamshaft bolts arrows finger t...

Page 228: ...ntaite camshaft on right cylinder head Press timing chain tensioner rail against timing chain white arrow to check that fastener holes are centered in sprocket slots black arrows when slack is removed...

Page 229: ...en sioner screw on 11 3 390 to 0 7 Nm 6 3 in lb T ghten camshaft sprocket bolts in the following order 1 Exhaust camshaft left head 2 Exhaust camshaft right head 3 Intake camshaft left head 4 Intake c...

Page 230: ...ply Three Bond 12098sealant to joint between cylinder head and timing chain cover lnstall upper timing cover bolts finger tight 4Remove cylinder head cover sealing gaskets from right cyl inder head co...

Page 231: ...r to levelof cylinder head Tightening torque Cylinder headcover nuts 10 Nm 7 5 it lb Tighten left upper timing chain cover retaining bolts in two passes Tightening torque Timing chain cover to head 10...

Page 232: ...emove cylinder head as described in 113 Cylinder Head Removal and Installation CAUTIOI C M52 TU M54enginesonly Donotletthe hydrauliclifters fallout as the camshaftcarrierisremoved Specialsuction cups...

Page 233: ...a valve guide is excessively worn it should be reamed to ac cept oversized valve stems Valve guide specifications are listed in Tabled Valve guide specifications Valve guides should be checked for wea...

Page 234: ...excessive oil consumption and smoke from the exhaust immediately after starting and during decel eration NOTE Valve stem oil seals shouldnot be reused If valves are re moved new valve stem oilseals s...

Page 235: ...o c A Valve seat angle 45 45 B Correction angle 15 15 outside C Correction angle 60 inside D Valve seat width intalte 1 65i0 25rnrn 1 25 0 25rnm 0 065c0 010in 0 049f0 010in exhaust 1 65c0 25rnm 1 65i0...

Page 236: ...hecked for fatigue To quickly check the springs line them up in a row Place astraight edge across the top of the springs Any spring that is significantly shorter than the others is worn and should be...

Page 237: ...engine I 17 22 Timing chains removing M52 engine 117 26 Timing chain installing M52 engine 117 30 bouble VANOS systemTunctidn 117 34 Double VANOS control unit 117 36 VANOS control unit removing M52 T...

Page 238: ...cific repair procedures referto the appropriate repair group 020 Maintenance 113 Cylinder Head Removal and Installation 119 Lubrication System 121 Ignition System 170 Radiator and Cooling System Speci...

Page 239: ...1 1 220 4 Upper timing cover Installationtool V 8 Tool No BMW 11 14111412 4 Crankshaft hub lockingtools 6 cylinderengine with 2 piece vibration dampener Tool No BMW 11 2 150 111 2 410 4 Cranltshaft lo...

Page 240: ...240 4 Crankshaft seal installation bushing 6 cylinde 4 Secondary chain tensioner locking pin set 6 cylinder Tool No BMW 11 3 290 11 3292 4 Secondary chain tensioner loclting pin V 8 Tool No BMW 11 3...

Page 241: ...390 Primary chain tensioner tool 6 cylinder Tool No BMW 11 4 220 VANOS sprocket wrench Tool No BMW 11 5 490 4 Double VANOS setup bracket M52 TUlM54 6 cylinder DoubleVANOS sprocltet setup tool M52 TU M...

Page 242: ...cable from battery CAUTIOIG a Disconnectingthebatterymay erasefault code s storedin control module memory Check for fault codes using spe cial BMW diagnostic equipment Prior to disconnectingthe batte...

Page 243: ...with vibration damper locatorpin While counterholding crankshaft loosen and remove crank shaft center bolt CAUTION Donot use flywheellocking tool to hold crankshaftstationary to loosen or tighten cran...

Page 244: ...r boltto draw seal in flush with timing case cover 4 Align hub with keyway and tap into place Insert new center bolt with washer shoulder arrow facing hub CAUTION Inspect woodruffl eyfor damage before...

Page 245: ...to disconnecting the battery read the battery dis connection cautions given in 001 General Cautions and Warnings Remove splash guard from beneath engine Remove engine cooling fan assembly See 170 Radi...

Page 246: ...per from crankshaft Oil seal replacement 4 Install cap BMW special tool 112 383 on end of crankshaft Install seal guide BMW special tool 11 2 385 over end of crankshaft Be sure to align groove with lt...

Page 247: ...lt Tighteningtorque Vibration damper hub to crankshaft 410 Nm 302 it ib Installation is reverse of removal noting the following Install drive belts See 020 Maintenance Install cooling fan See 170 Radi...

Page 248: ...all crankshaft holding tool BMW special tool 11 2 450 and remove and discard crankshaft center bolt NOJE Be careful to align hub locator pin to hole arrow inspecial tool 11 2 450 If needed use a pulle...

Page 249: ...firm contact with seal Tighten center screw in end of tool to draw out seal 4 Coat new seal with oil and use BMW special tool 11 1 220 and crankshaft center bolt to draw seal in flush with timing cas...

Page 250: ...System Replace under engine splash shield then reconnect nega tive battery cable ANBS CONTROL UNIT AND TIMINGCHAIN M52 ENGINE VANOS control unit removing M52engine NOTE Special BMW service tools are r...

Page 251: ...ing fasteners and remove coils Remove spark plugs NOTE Make note of ignition coilground strap locations DisconnectVANOS electrical harness connector A and oil line fitting B from VANOS control unit NO...

Page 252: ...rrows A and remove bracket Remove cable duct clips arrows B from front of VANOS control unit Rotate engine clocltwise and set camshafts to Top Dead Center TDC Cylinder 1 camshaft lobes will point towa...

Page 253: ...ming Chain 4 Unscrew and remove cylinder head cover studs arrows at rear of cylinder head Secure camshafts in TDC position using BMW special tool set 11 3 240 4 Remove access plugs arrows from VANOS c...

Page 254: ...pin NOTE Two types of secondary timing chain tensionersare used one with two holes and one with a single hole for the locl ing pin tool Remove VANOS control unit mounting fasteners at front of cylinde...

Page 255: ...emoval Rotateexhaust camshaftsprocketclocltwise asviewed from front of engine using BMW specialtool 115 490 untildetent position stop is reached 4 Apply a small amount of liquid gasket sealer Three Bo...

Page 256: ...mamountnecessaryto engagethe gear cup If thispro cedure is done incorrectlq the VANOS system may not fully function Install and tighten down VANOS control unit fasteners Tightening torques VANOS contr...

Page 257: ...mshaft locking tool set install camshaft gear bolt access plugs using new sealing washers and tighten Remove timing chain tensioning tool from side of cylinder head Install primary chain tensioner wit...

Page 258: ...edin controlmodulememory Prior to disconnecting the battery checlc for fault codes usingspecial BMW diagnostic equip ment Prior to disconnecting the battery read the battery dis connection cautions gi...

Page 259: ...shop rag to absorb leaking oil Disconnect cranltcase breather by squeezing at arrows Remove cylinder cover mounting fasteners and remove cylinder head cover NOTE The cylinder headcover mounting bolt i...

Page 260: ...t to 2 8 bar or 30 1 10 psi to air fitting 4 Measure gap A between secondarytiming chain tensioner and intake camshaft sensor wheel Make note of distance 4 Connect cable test BMW special tool 11 6 410...

Page 261: ...ol unit removing M52 engine and VANOScon trol unit installing M52 engine Remove special tools Cranltshaft locking tool Camshaft loclting tool set Air fitting VANOS cable adaptor Install VANOS oil line...

Page 262: ...operly timed the pistons can con tact the valves Remove VANOS control unit See VANOS control unit re moving M52 engine Remove radiator cooling fan and shroud See 170 Radiator and Cooling System Drain...

Page 263: ...Use only the special tools specified or equivalenthub holding tool Remove crankshaft hub Remove cylinder cover mounting fasteners and remove cyl inder head cover NOTE The cylinder head cover mounting...

Page 264: ...h either two holes shown or a single hole for the locking pin tool Remove intake and exhaust sprockets together with secondary chain Remove secondary timing chain tensioner bolts arrows and remove ten...

Page 265: ...to remove CAUTION Usecare when removing the cover from the cylinderhead gasket If the cover is stuck use a sharp knife to separate it from the head gasket If cylinder head gasket is damaged remove cyl...

Page 266: ...altools Inspecttiming chain and sprocltets and guide rails for wear Replaceworn parts NOTE Ifany of the sprockets are being replaceddue to wear the chain should also be replaced Install primary timing...

Page 267: ...e Install engine oil pan using a new gasket See 119 Lubrica tion System Mount primary timing chain sprocketto primary cha n so that arrow on sprocket faces up Mount sprocket to camshafl so that tapped...

Page 268: ...4 Preloadprimary timing chain by torquing adjustable primary chain tensioner BMW special tool 11 4 220 to 1 3 Nm 11 in lb Tighten exhaust camshaft sprocket bolts in two stage Tighteningtorque Exhaust...

Page 269: ...that cutout in tensioner pis ton engages chain rail Tightening torque Timing chain tensioner to tensioner sleeve 70 Nm 52 ft ib Install cylinder head cover mounting studs camshaft cover and cylinder...

Page 270: ...onents of the Double VANOS system are lntalte and exhaust camshafts with helical spline inserts Camshaft sprockets with adjustable gears VANOS actuators two position piston housing with inter nallexte...

Page 271: ...s with DME MS 43 0 modelyear2001 and newer the engine control module ECM detects camshaft position before the engine starts thereby adjusting camshaft timing immediately upon start up NOTE VANOS syste...

Page 272: ...seal cap 6 VANOS hydraulic pistonset screw CAUTION left hand thread tighten to 10 Nm 89 in lb 7 Nut M7 tighten to 14Nm 10 ft lb 8 Engine lifting hook 9 Stud M7 10 Nut M6 tighten to 10Nm 89 lb in 11 Ga...

Page 273: ...ng inside luggage compartment disconnect negative battery cable Prior to disconnecting the batteg read the battery discon nection cautionsgiven in 001 General Cautions and Remove engine cooling fan as...

Page 274: ...fitting Use shop rags to keep oil off drive belts Remove cylinder head cover fasteners and cover 4 Remove oil baffle cover from intake camshaft 4 D sconnect electrical connections from exhaust camshaf...

Page 275: ...ir line connected turn engine clocltwise using crankshaft center bolt at least two rotations until cylin der 1 is at TDC position intakeand exhaustcarnshafllobes as shown arrows Donotrotateenginecount...

Page 276: ...ags ready 4 Unscrew sealing plugs from VANOS control unit arrows NOTE Oil will drain from sealingplug bores Have a container and rags ready 4 Pull sealing caps straight out of VANOS control unit with...

Page 277: ...control unit installing M52 TU and M54 engines Clean contact edges of cylinder head face and double VANOS control unit and apply a thin coat of sealing com pound Three Bond 1209 8 or equivalent to sur...

Page 278: ...ounterclocltwise Tightening torque Hydraulic piston to splined shaft 10 Nm 89 in lb setscrew 4 Replace sealing caps inside VANOS control unit with BMW special tool 11 6 170 or short flat nosed pliers...

Page 279: ...of cylinder head at VANOS control unit Tightening torque Cylinder headcover to cylinder head M6 10 Nm 89 in lb Remainder of installation is reverse of removal Tightening torques Radiatorfan viscouscl...

Page 280: ...ioner rail Tighten adjusting screw on BMW special tool 11 4 220 Tightening torque Primary chain tensioner preload 0 7 Nm 6 in lb 4 Unscrew oil pressure pipe from VANOS control unit Remove banjo bolt f...

Page 281: ...ce BMW special tool 11 3 240 over camshafts ends and measure clearance of tool to cylinder head surface NOTE Ifthe exhaustside of the tool A isnotflush with the head adjust camshaft timing as describe...

Page 282: ...ake camshaftsprocket mounting nuts arrows by 1 turn Loosen exhaust camshaft sprocltet mounting bolts Release bolts A 112 turn Release nuts B 2 turns Pull out intake camshaft splined shaft out approx 1...

Page 283: ...BMW soecial tools 11 3 240 and 11 3 244 4 Preload primary chain tensioning rail Tighten adjusting screw on BMW special tool 11 4 220 Tightening torque Primary chain tensioner preload 0 7 Nm 6in lb 4...

Page 284: ...lb Sprocket assembly to camshaft M7 Torx screw A 20 Nm 15fl lb ivl6 mountingnut B 10 tdm 89 in lb Remove flywheel locking tool from transmissionbellhousing so that crankshaft is no longer locked Remo...

Page 285: ...al tool 11 3 450 from VANOS control unit Fit VANOS oil line banjo bolt with new seals Attach oil line to VANOS control unit Tightening torque Oil line to VANOS control unit banjobolt 32 Nm 24H lb Rema...

Page 286: ...8 Splined shaft 9 Secondary timing chain 10 Splined sleeve 11 Primary sprocket 12 Threaded stud 13 Secondary chain tensioner 14 Sprocket mounting nut 15 Spring plate 16 Splined shaft 17 Intakecamshaf...

Page 287: ...es D sconnect negative cable from battery CAUTION Disconnectingthebatterymayerasefault code storedin controlmodule memory Check for fault codes usingspe cialBMWdiagnosticequipment Prior to disconnecti...

Page 288: ...n cover CAUTIOIG Primarycamshaftchain tensioningpistonis underspring pressure Pressdown on secondarychaintensionerand lockinto place using BMW special tool 11 3 292 or a similar size wire Removeexhaus...

Page 289: ...m exhaust camshaft sprocket arrows Lift off exhaust and intake sprockets with secondary chain thrust spacer A and splined shaft B CAUTION Splinedshaftsfor bothintake andexhaust camshaftsshare the same...

Page 290: ...ry chain tensioner mounting bolts ar rows Remove tensioner while keeping locking pin in place 4 Removeprimary chain sprocket mounting studs arrows on exhaust camshaft 4 Lift primary chain sprocltet of...

Page 291: ...ng in cylinder head cavity remove timing chain cover bolts arrows Remove secondary chain lower guide bolts arrows Re move chain guide NOTE Bolt on intake camshaft side is long and extends into timing...

Page 292: ...emoved Thepistons cancontactthe valves Useappropriatecrankshaftholding tool whenloosen ing crankshafthub center bolt Using a drift of less than 5 mm diameter drive two locating dowels in left and righ...

Page 293: ...hat is worn or dam aged NOTE If any sprockets are being replaceddue to wear the chain shouldalso be replaced 4 Primary timing chain assembly 1 Primary chain tensioner 2 Chain tensioner rail 3 Cranltsh...

Page 294: ...ges Tighteningtorque Lower timing cover to cylinder bloclc M6 10 Nrn 89 in lb Install oil pan with new gasket See 119 LubricationSys tem Tighteningtorque Oil pan to engine bloclc M6 8 8 grade 10 9 gra...

Page 295: ...ensioner rail side 4 Insert BMW specialtool 114 220 in cylinder headand screw in adjustment screw by hand just until it contacts tensioning rail and chain slack is removed NOTE BMW special tool 7 1 4...

Page 296: ...t Tightening torque Exhaust camshaft locatingstud 20 Nrn 15 ft lb 4 Install secondary chain tensioner on cylinder head Make sure tensioner is locked in compressed position as described earlier Fit exh...

Page 297: ...ocltets in BMW specialtool 116 180 Positionspline gap on intaltesprocket arrow as shown and place secondary chain on sprocltets Carefully remove chain and sprockets from tool and slide onto camshafts...

Page 298: ...FRONT mark is visible Install mounting nuts arrows finger tight 4Worlting at exhaust side insert sprocket mounting Torx screws into threaded lioles arrows Initiallytighten screws to approx 5 Nm 44 in...

Page 299: ...mark is no longer visible installspring plate as shown Install exhaust camshaft impulse wheel aligning mark B with top edge of cylinder head A Install mounting nuts ar rows finger tight 4Pull out exha...

Page 300: ...ate by pressing on im pulse wheel while tightening mounting nuts arrows finger tight 4 Install BMW special tool 116 150 VANOSsetup bracket to front of cyl nder head timing case Tighten tool mounting n...

Page 301: ...on of rotation until cylinder 1 intake and exhaust camshaft lobes arrows face each other Secure crankshaft inTDC positionwith BMW special tool 11 2 300 4 Place BMW special tool 11 3 240 over camshaft...

Page 302: ...NOS operation with engine idling Tightening torques Coolantdrain plugto cylinder block 25 Nm 18 ft lb Radiatorcooling fan viscousclutch to coolant pump 40 Nm 30 ft lb Radiatordrainscrew to radrator 2...

Page 303: ...e top cover inplace Disconnect electrical harness connectors at ignitioncoils A Remove left and rightside ignitioncoil mountingfasteners and coils NOTE Make note of location ofground strap arrow Remov...

Page 304: ...linder head cover Unbolt lefl and right side cable ducts from fuel rail 4 Disconnect fuel injector electrical connectors Pry corner of wire lock clip to release connector from injec tor arrow Repeat f...

Page 305: ...s Remove engine drive belts alternator and AlC compressor See 020 Maintenance 4 Removevibration damper bolts arrows and remove damper 4 Mount BMW special tool 112 450 to crankshaft hub while aligning...

Page 306: ...11 2 450 and remove hub Remove upper engine oil pan See 119 Lubrication Remove alternator See 121 Battery Starter Alternator Remove retaining bolt for oil dipstick tube from upper timing chain cover...

Page 307: ...lve line and cap off line arrow Drain engine coolant and remove hoses from thermostat housing See 170 Radiator and Cooling System Remove water pump and thermostat housing See 170 Ra diator and Cooling...

Page 308: ...ial tool set 11 2 440 If necessary turn camshaft so that special tools are squarely seated on cylinder head Working at left cylinder head loosen intake camshaft sprocket bolts arrows CAUTION Counterho...

Page 309: ...th a plastic wire ties arrow 4 Remove lower timing chain cover bolts arrows and cover Remove wire ties supporting guide rails Q Remove sprocket from intake camshafts and remove timing chain If necessa...

Page 310: ...e being replaceddue to wear the chain should also be replaced Ifthe crankshaft sprocket requires replacement the oilpump drive sprocket andchain must be removed See 119Lubrication System for oilpump r...

Page 311: ...wire tie to hold rail against chain lnstall lower timing chain cover Clean sealing surfaces and check sleeves are properly seated Apply a thin coat of Three Bond 12098 to front and back of new seal Al...

Page 312: ...ghtening torque Sprocltetto camshaftflange 15 Nm 11 ft lb Remove BMW special tools 11 2 444144314411445 from right cylinder head Remove BMW special tools 11 2 4441443 421 446 from left cylinder head 4...

Page 313: ...cover Install right cylinder head cover with BMW special tool 11 1 411 to right cylinder head Fit cylinder head cover retain ing nuts to cylinder head cover studs at cylinders 1 and 2 first two cylin...

Page 314: ...joint between cylinder head and timing cover and at half moon shaped cut outs Tighten cylinder head cover nuts Tightening torque Cylinder headcover to head I 5 Nm 11ft lb Remainder of installation is...

Page 315: ...over straight up to remove Pry out caps from side covers Remove fasteners from beneath caDs Lift off covers 4 Remove air filter housing and ducts Disconnect mass air flow sensor and intake air tempera...

Page 316: ...mounting fasteners and coils NOTE Make note of location of groundstrap arrow Remove sparlc plugs Remove positive terminal cable from left cylinder head cover Unbolt cable ducts from fuel rail at left...

Page 317: ...nders 1 4 approximately I2turn NOTE When loosening bolts on camshaft sprocket counterhold camshaft using an 27 mm open end wrench If necessary machine wrench accordingly to prevent damage to head Repe...

Page 318: ...1 2 446 If necessary turn camshaft so that special tools are squarely seated on cylinder head Fit BMW special tool 11 2 443 to 11 2 4421446 Secure 11 2 443 to cylinder head with 11 2 444 installed int...

Page 319: ...tation so that remainino camshaft sprocltet retaking bolts are accessible Tighten remaining camshait sprocket retaining bolts Tightening torque Sprocket bolts to camshaft flange 15 Nm I1 It lb Remove...

Page 320: ......

Page 321: ...19 8 Engine Oil Pan I 19 10 Oil pan removingand installing 6 cylinder I 19 10 Lower oil pan removingand installing V 8 119 13 Upper oil pan removing and installing V 8 119 15 Component Replacement 119...

Page 322: ...are covered in 020 Maintenance CAUTIOG V8 engines The oilpump fasteners including the sprocket retainingnut areknownto vibrateloose This canresultinoil starvationandengine failure Be sure to check oil...

Page 323: ...oil filter replacement 6 cylinder 6 5 liters 6 9 US qt V 8 7 5 liters 7 9 US qt The oil pressure warning system consists of an oil pressure switch mounted in the oil circuit and an instrument panel w...

Page 324: ...in its place Unscrew oil filter cap in order to allow engine oil to drain back down into oil pan Disconnect harness connector from oil pressure switch and remove switch NOJE Thoroughly clean around th...

Page 325: ...rect before making tests Turn ignition switch on Warning light on instrument panel must light up Remove connector from oil pressure switch Warning light on instrument panel must go out NOTE Ifthe ligh...

Page 326: ...the engine is running check the oilpressureas described earlier Donotdrivethecaruntiltheproblemiscorrected The enginemaybe severelydamaged Crankshaftrear main seal replacement requires removal of the...

Page 327: ...requiredfor sliding the seal over the crankshaft is included with the lcit I CAUTION 1 Donot use BMW specialtool 1I 2213 mstallation guide with the newstyle seal Useonly the specialtoolsupphed with th...

Page 328: ...nkcase M6 10 Nm 89 in lb ME 22 Nm 16 ft lb Crankshaft rear main seal replacing V 8 Remove transmission See 230 Manual Transmission or 240 Automatic Transmission Manual transmission vehicles Removeclut...

Page 329: ...ove in stallation guide carefully Replace sealing washers under seal carrier mounting bolts Install seal carrier mounting bolts and torque to specilica tions lnstall oil pan bolts Remainder of assembl...

Page 330: ...ce 4 Remove oil dipsticlc guide tube Disconnect fuel lines and wiring harness from bracket A Disconnect oil separator hose B from base of guide tube Remove mountingbolt C from left engine mounting bra...

Page 331: ...raulic lines con nected to pump Suspend pump using strong wire See 320 Steering and Wheel Alignment NOTE Forbetter access to power steering assembly unbolt fluid reservoirandsuspend with wire Loosen u...

Page 332: ...taps witha rubbermalletshouldbreakit free Do notprythe oilpan loose When installing oil pan Thoroughly clean all old gasket material from mating sur faces and use a new gasket Apply a small amount of...

Page 333: ...olt usenew bolt 19 Nrn 14it lb Lower oil pan removingand installing V 8 The V 8 engine is equipped with a 2 piece oil pan The fas teners in V 8 engine oil pump assembly including the sprocket retainin...

Page 334: ...s at locations marked by arrows to guide new oil pan gasltet and oil pan into position and to prevent damage to sealing lip Install new oil pan mounting bolts threads coated with sealer Remove guide s...

Page 335: ...iace by installing bolts arrow in left and right hinges to lock hood in place 4 Remove engine top cover Earlyversion Pry off caps arrows and remove fasteners Late version Depress fasteners arrows and...

Page 336: ...ion System I Remove oil dipstick support from right cylinder head 4 Remove upper nuts arrow from left and right motor mounts 4 Attach BMW special tool 00 0 200 with tools i 201 202R04 208 engine suppo...

Page 337: ...parateeasily from upperpan a few taps witha rubbermalletshouldbreakitfree Donotpry the oilpanloose Remove N C drive belt tensioner Removeadjustment bolt B Remove retaining bolt A and remove tensioner...

Page 338: ...dipstick O ring seal Working at right side of engine remove oil return line from upper section of oil pan 4 Separate lower steering column from steering box Remove retainingbolt arrow from lower steer...

Page 339: ...MW special tool 31 2 220 and appropriate shop lift Remove subirame mounting bolts arrows and lower frame as far as possible sub Workingthrough loweroil panopening remove pump mount ing bolts arrows Re...

Page 340: ...eners including the sprocl etretaining nut using Loctite8or equivalentthread After adding engine oil start and run engine Raise engine speed to 2 500 rpm until oil pressure warning light goes out abou...

Page 341: ...the sealing washer Tightening torque Oil ressure switch to oil filter housins 27 Nrn 20 ft lb Oil level warning switch replacing 6 cylinder and V 8 4 Oil level warning switch is located at bottomof th...

Page 342: ...left hand threads 4 Version 2 M52 TU oil pump assembly 1 Oil pump pressure relief control valve assembly 2 Oil pump suction pick up and seal 3 Oil pump 4 Oil pump drive sprocket 5 Oil pump shaft lock...

Page 343: ...ver from oil pump and check for wear or scoring Spin oil pump shaft and check that gears turn smoothly Re place pump if gears spin with difficulty orany wear is present Inspect oil pressure relief val...

Page 344: ...p isaccessible Ifany fas teners are foundto beloose remove them andreinstallwith Loctite8andtorque to specifications Removeupperoil pan as describedearlier to gain accessto oil pump 4 If fitted remove...

Page 345: ...pump fully to stop arrow Reinstall pump Coat pump mounting fasteners arrows with Loctite 8or equivalent thread locking product Install and tighten Coat pump sprocltet shafl threads with Loctite 8 Rei...

Page 346: ...pan M6 8 8 grade 10 Nm 89 in ib M6 10 9 grade 12 Nm 9 ft lb M8 8 8 grade 22 Nrn 16 ft lb Oil drain plug to oil pan M12 25 Nm I8 ft lb Oil pump cover to oil pump M6 10 Nrn 89 in lb Oilpump sprocket to...

Page 347: ...retaining circlip Use a suitable drift to remove relief valve assembly from pump CAUTION There is highspringpressure in the relief valve 4 Inspect oil pump relief valve components and bore lor scor in...

Page 348: ......

Page 349: ...oubleshooting Oscilloscope diagnostic diagrams Misfire detection Ignition System Service 120 9 Ignitionfiring order 120 9 Disabling ignition system 120 10 Checking for spark 120 10 lgnition coil assem...

Page 350: ...ault code analysis also refer to these repairgroups 130 Fuel Injection ELE Electrical Wiring Diagrams OED On Board Diagnostics Special tools System diagnosis and testing of the ignitionsystem requires...

Page 351: ...tors and ignition test equipmentleads only while the ignition is off Switch multimeter functions or measurement ranges only with the testprobes discon nected Do not disconnect the battery while the en...

Page 352: ...system 1997 1998 1997 1998 1999 2002 4 All engines use a distributorless ignition system with individ ual ignition coils for each cylinder There is no distributor cap or ignition rotor 4 Each coil is...

Page 353: ...the DMEsystem wiring and test equipment leads only when the ignition is OFF Beforeoperating the starter without starting the engine for example when makinga compressiontest always disable the ignitio...

Page 354: ...IL warning lights as shown Misfire detection Engine m sfire in one or morecylinders may be caused by a var ety of malfunctionsin various subsystems The OBD II system ncorporated intothe engine managem...

Page 355: ...on 5 Combustion curve characteristics 6 Start of decay process 7 Termination oscillations Spark plug electrode temperature Enginecompression Spark plug wires 4 Short combustion period indicates large...

Page 356: ...defective 3 Downward peak arrow is missing completely ignition coil is defective 4 Defective ignition coil 1 Short spark period 2 The spark voltage line arrow is very slight Defective ignition coil 1...

Page 357: ...efective fuel injector Low compression in cylinder I 1 i O I I 1 i F h t i 1 J i 8 xt m2 2n Ignition firing order Normal secondary voltage patterns 4 cylinder pattern shown 4 Each ignition coil is mou...

Page 358: ...ntenance Check ng for spark is d fflcult on englnes wlth d str butorless ignitionsystems Try removingthe spark plugs and inspectingfor differences betweenthem A poor firing plug may be wet with fuel a...

Page 359: ...n Table c lgnition coil resistance Table c Ignition coil resistance Coil secondary resistance Spark plugconnector Bosch 1 O I ohm t 20 1 8 ir ohm t 20 Component Co l prlmary resistance Replace ignitio...

Page 360: ...TE Ifthe crankshaftspeed sensor pulse wheel is damaged the engine will have to be disassembleddown to the crankshaft to reolace the wheel Make certain ignition has been turned off Raise car and suppor...

Page 361: ...m bell housing Do not discard shims if present Installation isthe reverseof removal Clean mounting surface before installing new sensor and install shims if present If the flywheel was replaced the sp...

Page 362: ...ube D Remove filter housing mounting screws E Disconnect harness connector from VANOS solenoid and unscrew solenoid from VANOS control unit Be preparedwith shop rags to catch oil released from VANOS u...

Page 363: ...ory Tighteningtorque Exhaust camshaft sensor to cylinder head 10 Nm 7 ft lb Intakecamshaft position sensor replacing M62 and M62 TU engines Make sure ignition has been turned off 4 Remove top engine c...

Page 364: ...fold Remove intalte manifold as described in 113Cylinder Head Removal and Installation D sconnect knock sensor electrical harness connector A on left side of engine cylinder block Remove knock sensor...

Page 365: ...talledangleoftheknocksensorson theblocltbe foreremovalit Reinstallthesensorsinthesameposition Be sure to use a torque wrench when tightening the sensor mountingbolts Clean lknoclc sensor contact surfa...

Page 366: ......

Page 367: ...rator I 21 10 Alternator basic I 21 11 Alternator with multi function control MFR I 21 11 Water cooled alternator 121 12 Charging System Troubleshooting 121 12 Charging system quick check 121 13 Charg...

Page 368: ...r CAUTION Onlyusea digitalmultirneterwhen testingautomotiveelectri I cal components 4 Closed circuit current measurement adaptor Tool No BMW 61 2 300 Engine electrical system The alternator and starte...

Page 369: ...lt in immobilizer system EWS C l e a n Battery cables loose dirty or corroded Battery discharged Battery to body ground cable in trunk loose dirty or corroded Poor connection at starter motor terminal...

Page 370: ...ttery read the battery dis connection cautionsin 001 General Cautions and Warnings Models with MS43 engine management Allow at least 3 minutes to elapseafter turningignition ley to OFFpo sition before...

Page 371: ...tional or low maintenance batteries the most com mon method of testing the battery is that ofchecking the spe cific gravity of the electrolyte using a hydrometer Before testing the battery check that...

Page 372: ...oss battery terminals Open circuit voltage levels are giv en in Table c Open circuit voltage and battery charge If open circuit voltage is OK but battery still lacks power for starting perform a load...

Page 373: ...est is generally completed overnight using a multimeterwith a closedcircuitcurrent measurement adaptor with a recording function Check that battery voltage is 12 volts or higher If lower recharge batt...

Page 374: ...negativebat tery terminal Green LED light will go out NOTE Any electrical overloading will be indicatedat this point by lighting the redLED Ifthe redLED lights up check the adap tor connections Set mu...

Page 375: ...lution ofbak ing soda and water Always allow a frozen battery to thaw before attempting to recharge it Always disconnect both battery cables and remove bat tery from vehicle during battery charging Do...

Page 376: ...stall luggage cornpart rnent trim pieces Use BMW scan tool DlSplus or equivalent to read out airbag control module fault memory Correct faults then clear mem ory 1 1 4 Various versions of alternators...

Page 377: ...with multi function control MFR Alternator with multi function control MFR The multi function controlled alternator is used on 1999 2002 6 cylinder models 1998 2002 V 8 models 4 On cars with multi fun...

Page 378: ...n progressively reached Charging system diagnostics requires specialtest equip ment If the test equipment is not available chargingsystem fault diagnosiscan be performed by an authorizedBMW dealer or...

Page 379: ...tension Charging system checking CAUTIOI C Do not disconnectthe battery while the engine is running Damage to thealternatorand or engineelectronicsystems may result Only use a digital multimeter when...

Page 380: ...oming from terminal 61E of the alter nator connector Carefully connect the positive test lead to the wire using a piercing test lead end Turn ignition key on and check for voltage Voltage should be le...

Page 381: ...ess connector Disconnect electrical harness connector C from mass air flow sensor Remove air filter housing mounting screw D Disconnect vent tube E Loosen air intake duct clamp F Carefully lifl air fi...

Page 382: ...s the original Alternator manufacturer and ampere rating are nor mally marked on the alternator housing Disconnect negative battery cable CAUTION Priorto disconnecting the battery readthe battery disc...

Page 383: ...of alternator Release clip retaining wiring harness to alternator Rotate alternator forward and then up and out of engine com partment using care to not damage radiator C A U T I O e Protectradiator w...

Page 384: ...en in 001 General Warningsand Cau tions Remove radiator cooling fan and fan shroud See 170 Radi ator and Cooling System Drain engine cooling system See 170 Radiator and Cool ing System Remove alternat...

Page 385: ...contact In particular make sure ground connec tions between battery body and englne are completely clean and tight If no faults are found starter may be faulty and should be replaced If starter fails...

Page 386: ...negative battery cable CAUTIOI C Priorto disconnectingthe battern readthe baltery discon nectioncautionsinOOlGeneral Cautionsand Warnings Remove complete air filter hous ng Loosen intake duct hose cla...

Page 387: ...t to starter 5 Nrn 44 in lb Starter support bracket to engine 47 Nrn 35 ft lb Wlre terminals to slarter M5 5 Nrn 44 in lb M6 7 Nrn 62 in lb M8 13 Nrn 10ft lb Starter removing and installing V 8 engine...

Page 388: ...ssary for access remove right side oxygen sensor harness connector from retaining clip Working from end of transmission use suitable extensions and universaljoint to remove starter mounting bolts arro...

Page 389: ...ged or burned a new or rebuilt starter motor is needed Remove solenoid switch mounting screws arrows and separate solenoid from starter Unhoolc solenoid plunger from lever in starter drive Installatio...

Page 390: ......

Page 391: ...39 Evaporative emissions control MS 42 0 and MS 43 0 I 30 39 Engine control module ECM removing and installing 130 40 Siemens MS 42 0 and MS 43 0 ECM pin assignments 130 41 Bosch M5 2 M62 up to 911997...

Page 392: ...002 1 54 3 0 liter ISiemensMS43 0 54011999 2001 1 6 2 TU 4 4 liter l osch ME7 2 I OBI II software and hardware is incorporated in the engine management control systems The OED II system monitors compo...

Page 393: ...ls there are inexpensivegeneric OBD I1scan tool soft wareprograms and handheld units available Although these tools have limited capabilities as compared to the dedicated tools they are powerful diagn...

Page 394: ...tion Factory DTC scan tool Tool No BMW DISplus GTl MoDiC Ill 4 Fuel line plugs Tool No BMW 13 5 281 1 13 5 282 I 4 Fuel line clamp Tool No BMW 13 3 010 4 Fuel rail to pressure gauge fitting Tool No BM...

Page 395: ...tingthebatterymay erasefault code storedin memory Check for fault codes prior to disconnecting the battery cables Read the battery disconnectioncautionsin 001 General Warningsand Cautions a Connect an...

Page 396: ...fuel components Thor oughlycleanthe unions beforedisconnectingfuel lines When systemfaults are detected a diagnostic trouble code DTC is storedinthe enginecontrol module ECM The MIL also iiluminatesi...

Page 397: ...disconnecting the battery will not erase the fault memory The BMW dedicated 20 pin diagnostic linlc connector DLC is in the right rear of the engine compartment The 16 pin OBD I1diagnostic connector a...

Page 398: ...not presentand all earlier tests are OK relay is faulty and should be replaced If battery voltage is present continue testing If battery voltage is not present check fuse 109 80 amp fusible link under...

Page 399: ...e following problems Difficult to restart when engine is hot Engine starts then stalls Engine starts and runs only with accelerator pedal de pressed Disconnect electrical harness connector from MAF se...

Page 400: ...timing and airlfuel mixture requiredfor the engine by monitoringan appliedvolt age 5vdc to the sensor The voltage drop acrossthe sensor varies asthe coolant temperature sensorresistance chang es NOTE...

Page 401: ...CM to monitor intake air temperature for fuel and igntion adaptation The sensor is ocared in rne ntane man loldbehind the throttle housng The ECMmonitorsan applied voltage 5vdc to the sensor The volta...

Page 402: ...ensor is re placed the previous learned TPS settings must be cleared from the ECM using a BMW compatible scan tool If the throttle position sensor signal isdefective afault code is stored and the MILi...

Page 403: ...around the throttlevalve The idlespeedcontrol valve is mounted on the underside of the intake manifoldadjacent to the dipstick tube bracket Accessing the valve is best accom plished byfirst removingth...

Page 404: ...complished by first removingthe air filter housing and the throttle housing Disconnect intake air boot from throttle housing Unbolt throt tle body and lay aside Do not disconnect throttle cable or ele...

Page 405: ...You should feel a vibration or hear a buzzing Remove fuel injection harness from injectors by unclipping locking clip at each injector Lift harness off injectors CAUJ I O G Besure ignitionisOFFbefore...

Page 406: ...l to intake manifold 10 Nm 89 in lb Evaporative emissions overview On E39 MS 41 I cars the evaporative emissions system is combined with the tank ventilation system The evaporative system is monitored...

Page 407: ...tempumpsambientair intothe exhaust streamafler a cold engine start to reducethe warm uptime of the catalytic convertersand to reducesHC and CO emis sions The ECMcontrols and monitorsthe secondary air...

Page 408: ...d BMW dealer before replacing the ECM Disconnect negative battery cable Wait approximately one minute Priorto disconnectingthe battely readthe batterydiscon nectioncautionsin001 General Warnings and C...

Page 409: ...s see ELE Electrical Wiring Di agrams CAUTION a Always waitatleastone minuteafter turning offthe ignition before removing the connector from the ECM If the con nector is removed before this time resid...

Page 410: ...signal Mass air flow sensor signal Fuel consumption signal ECT signal Throttle position signal ground input output ground output output output ground output Traction control rear engine speed signal...

Page 411: ...tput inputloutput ground output input input input I I Battery voltage with key on or engine running Oxygen sensor signal ground 67 Idle speed control valve Power supply Oxygen sensor heater no 2 in fr...

Page 412: ...Bus low CAN Bus high Power supply Diagnostic connector TxD inputloutput inpuWoutput input input output Automatic transmission control module AGS Automatic transmission control module AGS Battery volta...

Page 413: ...patible scan tool See OBD On Board Diag nostics Only use a dgital multimeter for electrical tests Relay positions can vary Be sure to confirm relayposi tion by identifying the wiring in the socket usi...

Page 414: ...ostat Misfire detection Evaporative emission control and leak detection Malfunction indicator light MIL Performancecontrols Dual VANOS control Output of injection signal TI for fuel economy gauge Outp...

Page 415: ...130 25 Fuel injection CONTROL RESONANCE TURBULENCE VALVE CRANUSHAFT SECONDARY AIR MULTI FUNCTION ROLLING CODE...

Page 416: ...130 26 Fuel Injection Resonance turbulence 0021664...

Page 417: ...ilm mass air flow sensor Fuel pump relay Oxygen sensor heaters 4 Working in right rear of engine compartment Release interior ventilation filter cover latch A and re move cover Release plastic locking...

Page 418: ...re OK relay is faulty and should be replaced NOTE If no faults are found duringtesting butpoweris notreaching the ECMor other components check the fuses in the fuse carrier X8680 in the E box Mass air...

Page 419: ...e missingor blocked screens The screens affect air flow calibration Also inspect the sealina 0 rinas where the sensor insertsinto the air filter housing andintake boot Ensure the pin connectionsare cl...

Page 420: ...or In other words as the temperature rises resistance through the sensor decreases Ifthe ETC sensor input is faulty or non plausible the MIL is il luminatedwhen the MILis illuminatedwhen OED IIfault c...

Page 421: ...ixture and i T engine timing based on varying intake air temperatures i If the intaiteair temperaturesignal is implausible a fault code is set and the MIL is illuminatedwhen OBD I1fault criteriaare I...

Page 422: ...tle cable from the accelera tor pedalto the MDK unit The throttle cable is connecteddi rectlyto the integralpedal positionsensor PWG inthe MDK unit This sensor communicatespedal positionto the ECM whi...

Page 423: ...ottle housing Pull throttle cable upwards out of rubber retainer and unhoolc ball end of cable from throttle actuator 4 Remove nuts and bolts arrows retaining wiring harness to throttle housing Workin...

Page 424: ...clock wise and disconnect Removethrottle assembly mounting fasteners arrows and pull assembly off manifold Installation is reverse of removal Replace sealing ringbetweenthrottle assembly and intake ma...

Page 425: ...faulty Ifreplacing the EDK unit the adaptation values storedin the ECMmustbe clearedandthe newunitinitializedusing BMW special service tools CAUTIOIG Ifthe adaptationprocessisnotcompletedcorrectk the...

Page 426: ...manifold disconnect electrical bar ness connectors Idle control valve A Intake manifold resonance valve B Disconnect electrical harness connectors at oil pressure sender and oil temperature sender at...

Page 427: ...wise and disconnect Remove throttle assembly mounting fasteners arrows and pull assembly off manifold Installation is reverse of removal 0 Replace sealing ringbetweenthrottle assembly and intake manif...

Page 428: ...control valve regulates Idle speed by red rect ing air around the throttle valve The ldle speed control valve is mountedd rectly above the throttle housing Accessing the valve is best accomplished by...

Page 429: ...speed control valve with at tached bracket NOTE When installingidlespeedcontrol valve remove intake boot sealing ring from valve andinstallinto intake air boot Then install valve info sealing ring Ev...

Page 430: ...ECM Release interlor ventilation filter cover latch A and re move cover Release plastic loclting tab B Rotate air duct inward arrow to unloclt from bulk head and remove duct Release spring lock C to r...

Page 431: ...ng Di agrams CAUTIOW I A l a y s wait at least one mfnule after turningoff the ignition before remov ng he connecror irom rhe ECM If the con nector is removed before this time residualpower in the sys...

Page 432: ...Connector 1 2 3 I I I 5 1lnput ISignal intake camshaft position sensor camshaft position sensor 1 Componentlfunction Ground Ground Terminal 30 Voltaae SUDP V input Ground Ground Ground Input Ground X6...

Page 433: ...l intake air temperature Ilntake air temperature sensor I I I Throttle valve MS 42 0 Camshaft position sensor I Throttle valve MS 42 0 Hot film mass air flow sensor Camshaft position sensor i Throttle...

Page 434: ...eed control valve Idle speed control valve Shield knock sensor Resonance valve intake system Secondary air injection valve Connector X60004 40 pin Notes instrument cluster control unit Instrument clus...

Page 435: ...ot used 1 2 3 4 5 6 7 8 Connector X60005 9 pin Input Input Input Ground Ground Input Input Signal ignition coil 3 Signal ignition coil 2 Signal ignition coil 1 Not used Ground Ground Signal ignition c...

Page 436: ...s DTCs in the ECM and illuminate the MIL After ail testing is completed access and clear DTC fault memory using an OED I or BMW compatible scan tool See OBD On Board Diag nostics Only use a digital mu...

Page 437: ...2 1 system features The Bosch M5 2 1 system is used on 1998 540i models The M5 2 1 control module utilizesthe SKE standard shell con struction housing with 5 connectors and a combined total of 134pin...

Page 438: ...Fuel Injection...

Page 439: ...ed to as the DMEmain relay ECM relay powers ECM Ignition coils Fuel injection Evaporative leak detection pump 5 2 1 only Idle air actuator Camshaft sensors Evaporative emissions valve Hot film mass ai...

Page 440: ...e is not present check large red wire s in relay socltet See ELE Electrical Wiring Diagrams P tt Reinstallrelay and turn ignition on Gain access to underside of relay socket and checlc for ground at t...

Page 441: ...enough to causese rious burns Wearsuitableheavy gloves and other appropri ate protection NOJE Connector style may vary depending on system application Consult wiring diagram for system specific wiring...

Page 442: ...ing and replacing Thefuel iniectors are switched on and off oaened and closed by the ECM The injectors are connkcted to acom mon power source A ground signal from the ECM is used to open and close the...

Page 443: ...icate all fuel system O rings with assem bly lubricant Check that injector electrical connections are correctly fit ted andthat injectors are fully seated prior to installingiuel rail mounting bolts M...

Page 444: ...ck that idle speed control valve is buzzing Turn on AIC or shift car into drive ldle should remain steady or increase slightly Ifvalve is not buzzing or if idle decreases in step above stop engine and...

Page 445: ...har ness connector and checking across terminals If any faults are found replace throttle position sensor Engine coolant temperature ECT sensor testing and replacing Throttle position sensor M62 engin...

Page 446: ...ing is set to a conservativelsafeba sic setting 4 Disconnect ECT sensor harness A Checlc ECT sensor resistance using a multimeter at sensor terminals 3 and 4 Peel back protectiveboot B to ID termi nal...

Page 447: ...ents 540i models with ASC and DSC are fitted with a motor driv en auxiliary throttle valve and housingahead of the standard Throttle positionswitch throttle housing The ADS throttle valve controls eng...

Page 448: ...er Pneumatic pump chamber DME activated vacuum solenoid Reed switch provides switched voltage feedback signal to ECM The vacuum supply line is in the wiring harness from the en gine compartment and ru...

Page 449: ...en sensor heater signal Idle speed control closing winding Cvl 1 fuel iniection valve Note DME heated oxygen sensor 1 splice idle speed control valve cycled ground Cvl 1 fuel iniection valve lcvcled a...

Page 450: ...e Cvl 8 fuel iniection valve AIC comuressor relav sianal Heated oxygen sensor I in front of catalytic converter Heated oxygen sensor iI in front of catalytic converter Cyl 5 fuel injection valve cycle...

Page 451: ...ut input 81 input input input input output Not used I Knock sensor signal Not used Not used Coolant temperature 82 1 I Not used 83 I I Knock sensor Dual temperature swltch Not used Heated oxygen senso...

Page 452: ...sed Oxygen sensor heater signal Oxygen sensor heater ground Oxygen sensor heater ground Oxygen sensor heater ground Oxygen sensor heater ground Not used Input Input Output Output Output Heater oxygen...

Page 453: ...potentiometer DK Not used Injection signal Injection signal Not used Not used Input Input Input Ground Output Output Evaporative emission valve Ground point right hand drive Ground connector X6460 Hot...

Page 454: ...t sensor 5 6 7 12 Not used Ground Intake air temperature sensor Connector X60004 8 9 10 11 14 1 1Not used I Shield knock sensor Shield sensor I Shield sensor 3 Shield itnock sensor Input Knoclc sensor...

Page 455: ...D Communication link EWS Signal leak diagnosis pump Not used CAN Bus high CAN Bus low Not used Not used Start signal Terminal 1 signal Terminal 1 signal Terminal 1 signal Terminal 1 signal Ground Term...

Page 456: ...ate the MIL After all testing is completed access and clear DTC fault memory using an OBD I1 or BMW compatible scan tool See OBD On Board Diag nostics Only use a digital multimeter for electrical test...

Page 457: ...ry state of charge CAN Bus communicationswith instrument cluster EWS 111 3 3 rolling code ISN interface Ignition knock sensors DSC dynamic stability control torque reduction Monitoring and control of...

Page 458: ...e fuel filter trans fer the fuelpressure regulatorfrom the oldfilter to the new fil ter Engine idle speed control is a function of the EDK The M62 TU engine does not use a separate idle control valve...

Page 459: ...phasesof engine operation Iffaults aredetected the EDK motorisswitchedoff and fuel injectioncut off is activated The engine continues to run extremely roughlyat idle speed EDK adaptation When the EDK...

Page 460: ...t NOTE Relay locations can vary Confirm relay identificationby matching wiring colors and terminal numbers 4 Check for voltage at terminal 6 of main relay socket 30 red wire If battery voltage is pres...

Page 461: ...he sensor decreases Ifthe ETC sensor input is faulty or non plausible the MILis il luminatedwhen OBD IIfault criteria are exceeded The ECM assumes a substitutevalue 80 C 176 F to maintainengine operat...

Page 462: ...nsor tip Tighteningtorque Oxygen sensor to exhaust system 50 Nm 37 ft lb Fuel injectors removing and installing The ME 7 2 system uses ball seattype fuel injectors This de sign prov desprecise seal ng...

Page 463: ...fuelhose to absorbanv leakinqfuel Plugallopen fuellines Lifl fuel rail and injectors straight up to remove lnstallation is reverse of removal Use new injector seals and clamps during installation Mas...

Page 464: ...amber DME activated vacuum solenoid Reed switch provides switched voltage feedback signal to DME The vacuum supply line is inthe wiring harness from the en gine compartment and runs down the driver s...

Page 465: ...of between 10 C 50 F and 40 C 104 F and continues to operate for a maximumof 2 minutes at idle speed The electric air pump draws in ambient air and supplies it to the checlc valve The vacuum vent val...

Page 466: ...Input Input output input Output Ground Ground Ground Ground Ground Ground Heated oxygen sensor heater ground Back up light signal CAN BUSLow CAN Bus High Not used Not used Heated oxygen sensor heater...

Page 467: ...ule relay Connector X60003 Ground Output Input Ground Output Input Input Output Output Input Pin 1 2 3 Not used Ground for electronic components Voltage supply for hot film mass air flow sensor Signal...

Page 468: ...52 Connector GO004 Knock sensor 4 signal Knock sensor shield Oil level thermal Injection signal Injection signal Electric throttle actuator signal Not used Ground Crankshaft position sensor signal No...

Page 469: ...Pedal position sensor Pedal position sensor Engine speed signal output TD Not used Signal back up light DM TL diagnostic module tank leakage Signal oil level sensor Right rear wheel speed signal Clutc...

Page 470: ...ignition coil Cylinder 2 ignition coil Cylinder 3 ignition coil Ground point 3 4 5 7 8 9 Output Output Ground Terminal 1 signal Terminal 1 signal Ground Output Output Output Terminal 1 signal Termina...

Page 471: ...nder models I 60 1 0 Fuel pressure gauge installing V 8 models I 60 1 1 Fuel delivery testing I 60 12 Fuel Pump and Fuel Level Sender 160 15 Fuel level sender right side and fuel pump removingand inst...

Page 472: ...nd engine management DME systemsare referredto by man ufacturercode If necessary see 100 Engine General for modelyear engine code and DMEapplications NOTE Fuel filter replacement is coveredin 020 Main...

Page 473: ...ECM NOTE 1997V 8models 540i with Bosch DMEM5 2are not equipped with an OBD I1running losses monitoring system Fuel tank evaporative control system models with DME MS42 0 4 The main components of the...

Page 474: ...n Board Diagnostics When leak testing observe following conditions to obtain plausible results Fuel tank 1 to I full 0 Vehicle parked for at least 2 hours to allow fuel to reach room temperature Ideal...

Page 475: ...el Fuel may spray on the hot bulb causing a fire 0 Make sure the worlcarea is properly ventilated CAUTION Prior to disconnectingthe battery read the battery discon nection cautions given in 001 Genera...

Page 476: ...1 englne manage ment Fuse F54 15A luggage compartment fuse panel 6 cylinder models with Siemens DME MS43 engine man agement Fuse F22 25A glove compartment fuse panel V 8 models with Bosch DME M7 2 Fu...

Page 477: ...r additional wiring information NOTE The fuel pump will run as soon as thejumper wire Is at tached Thejumper wire should be 1 5 m d 14 ga and include an in line fuse holder with a 15A fuse To avoid fu...

Page 478: ...s on connector NOTE Fuelpumppower issuppliedthrough the white blue wire Ground is suppliedby the brown wire With jumper wire connected in place of fuel pump relay as described above check for battery...

Page 479: ...r grommet from center of access cover insu lation Peel back insulation at perforations to expose fuel tank ac cess cover Remove right side cover to expose electrical harness con nector Disconnect harn...

Page 480: ...ressure in the tank before working on the tank or lines 4 Attach fuel pressure gauge to BMW special tool 13 5 220 T fittlng or equivalent and attach to schraeder valve WARNING Thefuelpressuregauge mus...

Page 481: ...ick release sleeve above that discon nects the line when depressed WARNING Fuel In fuel line is underpressure approx 3 5 bar or 45 75psi andmaybe expelledunderpressure Donotsmoke or work near heaters...

Page 482: ...ery volume which can be affected by restrictions such as clogged fuel filter or fuel pick up port in the fuel tank System pressure testing 1 Fuel pressure regulator outer seal 4 System pressure is cre...

Page 483: ...off re turn hoseto fuel tank Pressureshould rise rapidly If not fuel pump is most likely faulty If pressure rises the fuel pressure regulator is most likely faulty If pressure is too high checlc retur...

Page 484: ...ressure reading Observe fuel pressure reading after approximately20 mln utes The pressure should not drop more than 0 5 bar from system pressure listed in fuel pressure specifications in ac companying...

Page 485: ...p NOTE The compensating siphonpump maintains the fuel level be tween the right and left tank lobes If fuel level sender resis tances are not approximately the same on left and right remove the senders...

Page 486: ...f fuel underpressure Removetank sending unit Releaseelectrical harness by sliding lock back then lifting off connector a Disconnect hose arrow Unscrew threaded collar from fuel pumpifuel level sender...

Page 487: ...ed See 020 Maintenance Tighteningtorque Tank collar locking ringto tank 35 Nm 26lb ft Fuel level sender left side removing and installing The procedurefor removingand replacingthe left sidefuel level...

Page 488: ...l CAUTIOW Do notbendfuellevelsenderarm 4 Once level sensor unit has been lifted partially out of tank disconnect tank siphon hose by pressing tabs arrows Installation is reverse of removal Attach tank...

Page 489: ...of tank disconnect tank siphon hose by pressing tabs arrows The tank lobe siphon pump is heldto baffle in bottomof right tank lobe Release retainer and lift out pump Installation is reverse of remova...

Page 490: ...r heat ers or other fire hazards Start engine and allow to run 10 15 seconds to fill fuel com pensating siphon assembly This will allow both lobes of fuel tank to he drawn off through fuel filler pipe...

Page 491: ...nd Warnings Remove rear seat bottom cushion Peelforward lip of carpet from beneath seat cushion and carefullypeel back insulation to expose fuel tank access cover on left and right sides Re move cover...

Page 492: ...chafed dr ed out or cracked lnspect heat shield and replace if corroded Inspect rubber buffers and h e r s on fuel tank support straps and on underside of body Replace rubber parts that are hardened...

Page 493: ...iackis notadequatesupport Remove left rear wheel and wheel housing inner shield 4 Remove plastic nut A and disconnect hose B 4 Tilt vent tank down and loosen or cut off hose clamps arrows Pull hoses o...

Page 494: ...16 rnm dia 3 Nm 27 in lb Running losses 312 way valve removing and installing The running losses 312 way valve is located under the car beneaththe driver s seat just ahead of the fuel filter A protec...

Page 495: ...rotective panel from fuel filter and 312 way valve Clamp off fuel lines at 312 way valve 4 To remove 312 way valve V 8model shown Disconnect electrical harness connector A from valve Remove vacuum hos...

Page 496: ......

Page 497: ...m pressure test I 70 9 Combustion chamber leak test I 70 10 Thermostat I 70 1 0 Cooling System Service 170 10 Coolant draining and filling 6 cylinder models 170 10 Coolant draining and filling V 8 mod...

Page 498: ...nditioning Special tools Specialtools are necessaryfor belt drivenfan clutch removal and also for pressuretestingthe coolingsystem 4 Cooling fan counterhold wrench Tool No BMW 11 5 030 4 Cooling fan w...

Page 499: ...he en gine The belt driven pump circulates coolant through the system whenever the engine is running Thermostat Two types of thermostats are used inthe cars covered bythis manual 6 cylinder models bui...

Page 500: ...f the electronics the mechanical function of the thermostat acts as a fail safe Radiator and expansion tank The radiator is a crossflow design An expansion tank pro vides for coolant expansionat highe...

Page 501: ...e When the vehicle is first started the ECM activates the elec tric fan briefly at 20 of its maximum speed then switches off This isfor diagnostic monitoring The voltage generated by the fan when it s...

Page 502: ...start up the engine coolant is heated more quicltlythan the transmissionfluid Heat from engine coolant is usedto warm upthe ATF faster reducingdrag inthe trans missionand improvingfuel mileage Once t...

Page 503: ...the coolant while the engine is hot or overheated If it is necessary to add coolant to a hol system do so only with the engine running and coolanl pump turning Toavoid excess silicategel precipitation...

Page 504: ...vis cous clutch cooling fan removing and installing Remove drive belt from coolant pump pulley See 020 Maintenance Firmly grasp opposite sides of pulley and check for play in all directions Spin pull...

Page 505: ...BMW special tools 170 002117 0 005 or equivalent to expansion tank Pressur ize system to specification listed inTable a Cooling system test pressures Pressure should not drop more than 0 1 bar 1 45 p...

Page 506: ...m tests indicate trouble the thermostat may be faulty In V 8 models and 6 cvlinder models nroduced afler 911998 M52TU or M54 eng ne rheelecrricaily heated rhermostal IS mon tored by heOBD I I diagnost...

Page 507: ...Before refilling radiator Switch ignition to ON Do not start engine Set temperature controls to full warm Set blower control to low Using a coolant mixture of 50 antifreeze and 50 distilled water fill...

Page 508: ...gnedfor I the purpose A floorjack is not adequate support 1 Remove splash shield from under engine Loosen radiator bleed screw at top radiator fining arrow Remove cap from radiator expansion tank With...

Page 509: ...g a coolant mixture of 50 antifreeze and 50 distilled water fill expansion tank slowly Continue until coolant emerges from bleedscrew Cooling system capacity is listed in Tabled Cooling system capacit...

Page 510: ...e until it reaches operating temperature After engine has cooled recheck coolant level Top up so that coolant level indicator is at MAX If trapped air cannot be bled manually pressure bleed sys tem us...

Page 511: ...an mounting bolts and sepa rate viscous clutch from fan Installation is reverse of removal Tightening torques Clutch nut to pump Without BMW tool 115 040 40 Nm 29ft lb With BMW tool 115 040 30 Nm 22 f...

Page 512: ...an shroud See Me chanical viscous clutch cooling fan removing and in stalling Disconnect coolant hoses from thermostat housing Remove thermostat housingfrom front of engine Remove thermostat Note ther...

Page 513: ...and engine block See Coolant draining and filling 6 cylinder models CAUTION Allow coolingsystem to coolbefore openingor drainingthe system Remove cooling fan and fan shroud See Mechanical vis cous clu...

Page 514: ...ECM for stored fault codes Drain radiator and engine block See Coolant draining and filling V 8 models WARNING Allow coolingsystem to coolbefore openingor draining the system Disconnect mass air flow...

Page 515: ...n lb Thermostat cover to coolant pump 10 Nm 89 in lb Coolant pump replacing 6 cylinder models The engine coolant pump is mounted in the front of the en gine in the timing chain cover Drain cooling sys...

Page 516: ...18 It lb Radiator drain plugto radiator 2 3 Nm I8 27 in lb Coolant pump replacing V 8 models I 1 The engine coolant pump is mounted in the front of the en gine in he timing chain cover 1 Thermostat ho...

Page 517: ...ed to the block using different length bolts 0 Bolts A M6 X 105mm 0 Bolts 8 M6 X 35mm Slide coolant pump away from coolant pipes arrows while being careful not to dislodge pipes from fittings at rear...

Page 518: ...r V 8 and 6 cylinder mod els Raise front of car and support safely WARNING Make sure the car is stable andwell supportedat aNtimes Usea professionalautomotiveliff orjaclcstands designedfor Remove spla...

Page 519: ...ard and off lower retaining lugs Push shroud back to expose expansion tank vent line Re move line Using 32 mm wrench BMW special tool 115 040 on fan clutch nut arrow turn wrench in a clockwise directi...

Page 520: ...stem See Coolant draining and filling 6 cylinder models or Coolant draining and filling V 8 models Tighteningtorques Engine block drain plugto block 25 Nm 18 it lb Radiator drain plug to radiator 2 3...

Page 521: ...arness connector from coolant level sensor C Pushtop of expansiontank toward engine and disconnect bleed hose Lift expansion tank to free it from lower mounts then lift straight up to remove Installat...

Page 522: ......

Page 523: ...moving and installing M62 engine Oxygen Sensors 180 9 Oxygen sensors precatalyst replacing M52 TU and M54 180 9 Oxygen sensors post catalyst replacing M52 TU and M54 180 9 Oxygen sensor replacing M52...

Page 524: ...mmablechemicalsnear a hot cataiyiic converter Corroded exhaust system components crumble easily and often have exposed sharp edges Toavoid injury wear eye protection and heavy gloves when working Exha...

Page 525: ...erlfrontexhaustpipeassemblyis to be replaced transfer the oxygen sensors to the newpipe s Tighteningtorque Oxygen sensor 55 Nm 41ft lb installation is reverse of removal Make sure there is at least 20...

Page 526: ...lledon the car Re placement of the front or middle mufflershould only be done with the exhaust removedfrom the car Mark length of new muffler pipe s on old system Use exhaust pipe cutter to cut pipe s...

Page 527: ...ose Neverwork undera car thatissupportedsolelybyajack Disconnectsecondaryair check valve and pipefrom exhaust manifold Unbolt front exhaust pipe from exhaust rnanifold s Remove exhaust support bracket...

Page 528: ...m IHin With exhaust system cold raise and support car for access to exhaust system WARNING Donotworlc underaliftedcar unlessitissolidlysupportedon jack stands designedfor thatpurpose Never worlc under...

Page 529: ...lylimited Ifremovingexhaust manifoldsaspartofadditional engine worlc such as cylinder headremoval it may be easier to first removeengine With exhaust system cold raise and support car for access to ex...

Page 530: ...t on the screws on the fenders Remove nut at top of engine support on left side Raise engine at front suspension lug a maximum of 25 mm I O in Release clamping bolt and nut arrow and slide universal j...

Page 531: ...oxygen sensor using special oxygen sensor removal socket Installation is reverse of removal New sensor threads come coated with anti seize paste If reusing a sensor apply thin coat of anti seize past...

Page 532: ...rque Oxygen sensor to manifold 50 Nm 37 ft lb Oxygen sensor replacing M52 and M62 engine The sensors are installed at the front and rear of the catalytic converters I WARNING I I Allow componentsto co...

Page 533: ...o cylinder head 5 Clamping sleeve 6 Post catalyticconverter oxygen sensor 7 Pre catalyticconverter oxygen sensor 8 Hanger 9 Rear muffler 10 Vibration dampener 11 Center support bracket 12 Clamping sle...

Page 534: ...ission bracket 2 Center support bracket 3 Front muffler 4 Clamping sleeve 5 Vibration dampener 6 Hanger 7 Rear muffler 8 Hanger 9 Center muffler 10 Oxygen sensors post catalytic converter 11 Oxygen se...

Page 535: ...e Front muffler Rear muffler Hanger Vibration dampener Clamping sleeve Center muffler Hanger Gasket front pipeto manifold 10 Exhaustmanifold catalytic converter assemblies 11 Oxygensensors post cataly...

Page 536: ...er muffler 5 Hanger 6 Rear muffler 7 Clamping sleeve 8 Oxygen sensors post catalytic converter 9 Oxygen sensors pre catalytic converter 10 Left side catalytic converter 11 Sealing rings 12 Leftfront e...

Page 537: ...rs post catalytic converter 2 3 Hanger 4 Rear muffler 5 Clamping sleeve 6 Hanger 7 Center muffler 8 Clamping sleeve 9 Catalyticconverter left side 10 Catalyticconverter rightside 11 Exhaust manifoldlc...

Page 538: ......

Page 539: ...200 Transmission Genera General 200 2 Automatic Transmission Drivetrain 200 2 Transmission Lubricants Manual Transmission 200 2...

Page 540: ...e rear wheels 4 Due to different power characteristics and performance re quirements various manual transmissions are used in mod els covered by this manual Manual transmission applications are given...

Page 541: ...ns Model Year Engine Transmission 526 from 911999 M52 TU ASS 360R 5251 from 312001 M54 ASS 3252 5301 to 312001 M54 ASS 390R 530i from 312001 M54 ASS 3252 540i from 111997 M62 TU ASS 4402 Automatic tra...

Page 542: ...yellowlabel reads MTF LT I is used See 230 Manual Transmission Automatic transmission is filledwith either Dexron IllATF blacktransmission ID plate readsATF Oil or special life time oil greentransmis...

Page 543: ...d installing 6 cylinder engine 210 12 Flywheel removingand installing V 8 engine 210 13 Transmission pilot bearing replacing 210 15 Clutch installing non SACcomponents 210 16 Clutch installing new SAC...

Page 544: ...V 8 and 1998 and later 6 cylinder models use a self adjusting clutch SAC NOTE See 200 Transmission Generalfor transmissionapplica tion information Special tools Some special tools and techniquesare re...

Page 545: ...010 4 Clutch disc lining gauge Tool No 21 2 080 4 Clutch disc centering mandrels non SAC clutch Tool No 21 2 141 21 2 142 21 2 200 21 2 201 4 Clutch disc alignment tools SAC clutch Tool No 00 5 500 h...

Page 546: ...chhydraulic system shares the fluidreservoirandflu idwith the brake hydraulic system Clutch hydraulic system bleeding and flushing If the clutchlbralte fluid is murky or muddy or has not been changed...

Page 547: ...lead to corrosion problems in the clutch and brake hydraulic systems nd will also lower the brake fluid boiling point Dispose of brale fluid properly Raise and safely support vehicle WARNING Make sur...

Page 548: ...crew and detach special tool 21 5 030 from slave cylinder CAUTION Do not remove toolifhydraulicsystem ispressurized Reinstall slave cylinder Tightening torque Slave cylinder to transmission case 22 Nm...

Page 549: ...aulic supply hose from brake fluid reser voir Plug reservoir outlet and hose 4 Remove lower dash trim panel fasteners A and B Lowertrim panel and disconnect wiring harnesses on back side of panel Remo...

Page 550: ...l CAUTlON Switchmodule mustsnap firmly intoplace on the mastercyl inder during installation Tightening torques Clutch master cylinder to pedal cluster 10 Nm 89in lb Fluidline to mastercylinder or slav...

Page 551: ...de grease MolyltoteIB Longterm or equivalent During installation be sure pushrod tip engages recess in clutch release lever Fill fluid reservoir with clean fluid Bleed clutch hydraulics as described e...

Page 552: ...n addition the procedure for re installing a previously used SAC differs from the procedure for installing a new SAC Be sure to readthe SAC installation procedure through before starting the job The p...

Page 553: ...ingasbestos Donot use compressed air to cleancomponents Donotgrind heat weld orsandon or near anvasbestos materials Pull release bearing off transmission input shaft Remove clutch release lever by sli...

Page 554: ...ansmis sion input shaft splines 4 Checlc release bearing ball stud and spring retainer Replace if damaged or worn CAUTION On S6S420G transmission always replacereleasebearing ball studandretainersprin...

Page 555: ...lornslallllylvheel Donotreusellle oldslrelch lypebolls Donor rnsrallbolls wrlh Loct lo or srm I ilarthreadlicking compound 1 Flywheel removing and installing V 8 engine Inspect flywheel for scoring h...

Page 556: ...s arrows Lightly oil flywheel mounting bolt threads and torque to specification Tightening torque Flywheel to crankshaft 105 Nm 77 ft lb CAUTIOI C Do not reinstallflywheelbolls with LoctiteCTJor simil...

Page 557: ...end Subtract length of pulse sensor A from distance to pulse tooth from mounting area on transmission This resulting measurement is the pulse sensor air gap Use shims avail able from BMW to adjust ai...

Page 558: ...5 speed transmission Special tool 21 2 130 Install flywheel lock BMW special tool 11 2 170 4 Install pressure plate and clutch disc to flywheel Install and tighten bolts hand tight C A U T I O G Besu...

Page 559: ...ngclutch SAC pressureplate The SAC pressure plate when new comes from the factory with a lock plate at the centerwhich maintainsspringtension on the self adjustingsprings This loclting ringmust not be...

Page 560: ...te maymake snapping noises while being unscrewed Using large bolt pull out clutch centering tool Remove flywheel locking tool 4 Inspect and clean release bearing lever Apply a thin coat of grease to r...

Page 561: ...rows SAC adjustment ring is now in its original position 4 Install BMW special tool 21 2 170 on SAC pressure plate Fit fingers of special tool in slots above dowel pin bores Tighten down knurled nut a...

Page 562: ...e bolt Remove flywheel locking tool Inspect and clean release bearing lever Apply a thin coat of grease to release bearing lever lubrication points lnstall re lease bearing Bearing tabs A align with c...

Page 563: ...00 rpm Upshift and downshift through all the gears at 3500 4000 rpm On medium grades approx 12 and up start off at ap prox 2500 rpm for the first 5 or so times Tightening torques Clutch slave cylinder...

Page 564: ......

Page 565: ...ransmission transmission installed 230 12 Transmission Fluid Service 230 6 put shaft seal replacing Transmission fluid level checking 230 6 transmission 230 15 Transmission fluid replacing 230 6 Trans...

Page 566: ...ain Special tools BMWspecifiedtools are requiredfor removaland installation of the manualtransmission as well as the removaland instal lation of seals at the transmissioninput output and selector shaf...

Page 567: ...Tool No BMW 23 0 040 Selector seal extractor Tool No BMW 23 0 210 4 Selector seal installationdrifl Tool No BMW 23 0 220 4 Input shaft seal puller slide hammer Tool No BMW 23 0 490 4 Output shaft flan...

Page 568: ...drift Tool No BMW 23 2 340 23 2 430 24 0 110 4 Output shaft seal installation drift 6 speed transmission Tool No BMW 23 2 480 4 Input shaft seal installationtools 6 speed transmission Tool No BMW 23...

Page 569: ...Engine Transmission 5251 Sedan 2001 2002 M54 Getrag S5D 250G Sport Wagon 2001 2002 M54 ZF S5D 3202 5281all 1997 2000 M52 M52 TU ZF S5D 3202 530i Sedan 2001 2002 M54 ZF S5D 3202 540i Sedan 1997 2002 M6...

Page 570: ...g B Insert finger into hole to check fluid level If fluid level is up to bottom of filler hole finger is wetted by transmission fluid level is correct NOTE Check and fill transmission with car on leve...

Page 571: ...lt Transmission unit Fluid change Getrag S5D 250G 1 1 liter 1 2 US qt 1 0liter 1 l US qt Getrag S6S 420G 1 9liter 2 0 US qt 1 7liter 1 8 US qt ZF S5D 3202 1 3liter 1 4 US at 1 2 liter 1 3 US qt Tighte...

Page 572: ...sionjack Disconnect driveshaft at transmission and tie to side See 260 Driveshaft 4 Remove transmission crossmember Where applicable release electrical harnesses from transmission crossmember Remove t...

Page 573: ...al notingthe fol lowing Install driveshaft using new loclc nuts Check transmission oil level topping up as necessary Tightening torques Aluminum driveshaftto flex disc MI2 use Dacromet coatedwashers 9...

Page 574: ...electrical harnesses from transmis sion crossmember Remove transmission mounting bolts A Remove transmission crossmember bolts 6 Where applicable remove bolts C Tilt down rear of transmission CAUTIOI...

Page 575: ...tages Tightening torques Output flange to output shaft Stage I 190 Nm 140ft lb Stage II after loosening 120 Nm 89ft lb Remainder of installation is reverse of removal notingthe fol lowing Install driv...

Page 576: ...ansmissionoutput flange and hang driveshaft to side See 260 Driveshaft Remove transmission crassmember If applicable release electrical harnesses from transmis sion crossmember Removetransmission and...

Page 577: ...ation drift BMW special tool 23 2 480 or equivalent to drive seal into housing as far as it will go Inspect sealing surface on output flange Replace ifworn or damaged Coat sealing lip of seal sealing...

Page 578: ...flange to out put shaft Stage I 190 Nm 140ft lb Stage II after loosening 120 Nm 89 it lb Use BMW special tool 23 2 470 to installflange nut retaining plate Remainder of installation is reverse of remo...

Page 579: ...mission oil and push over protective sleeve up to transmission housing Remove protective sleeve from input shaft Use BMW special tool 23 2 430 or similar drifl to drive seal until fully seated ZF S5D...

Page 580: ...r Torx head bolts at the bellhousing WARNING Male sure the carisstableandwellsupportedat alltimes Use a professionalaulomorive lift orjack slanos des gned lor the purpose A floorjack is nor adequare s...

Page 581: ...k up light switch on transmission Free harnesses for oxygen sensors and back up lights from crossmember and transmission Remove transmission crossmember Remove transmission mount bolts A Remove transm...

Page 582: ...pacer 0 V 8 vehicle Turn front wheels to preventstrain from being placedon center tie rod All vehicles Tiltingthe engine to lowerthe transmission can leadto damage to various componentsdue to lack of...

Page 583: ...ghly clean input shafl and clutch disc splines Light ly lubricate transmission input shaft before installing Be sure bellhousing alignment dowel sleeves are located correctly Replace damaged sleeves C...

Page 584: ...t ib 100 Nm 74 ft lb M14 140 Nm 103 ft lb Rubbermount to transmission or crossmember 21 Nm 15 ft lb ME Slave cylinder to transmission 22 Nm 16 ft lb Transmission crossmember to chassis or transmission...

Page 585: ...and filling 240 7 240 2 Automatic transmission fluid 240 4 pan and strainer 240 9 Troubleshooting 240 4 Transmission Removal and Installation 240 10 Automatic Transmission Fluid Transmission removing...

Page 586: ...CAUTION ATFdoes notcirculate unlessthe engine is running When towinganautomatictransmissionvehicle usea flatbedtruck or raise the rear wheels off the ground Special tools Some special tools are requir...

Page 587: ...4 Tran5mission support for use with transmissionjack A5S 560Z transmission Tool No BMW 24 0 170 4 Transmission support for use with transmissionjack A5S 4402 transmission Tool No BMW 24 0 250 4 Torqu...

Page 588: ...911999 M52 A4S 310R 5281 from 911999 M52TU A5S 360R 5251 to 312001 M54 A5S 390R 5251 from 312001 M54 ASS 3252 530i to 312001 M54 ASS 390R 530i from 312001 M54 A5S 3252 540i from 111997 M62TU A5S 4402...

Page 589: ...special BMW diagnostic equipment Some minor automatictransmissionproblemscan becor rected by changingthe automatictransmissionfluid ATF and filter Beginby checkingATF level and condition Checlc to se...

Page 590: ...rrent information regarding transmission operating fluids ATF level checking Check ATF level if there is evidenceof a leak a complaint re latedto fluid level or afler transmission repairs The automati...

Page 591: ...ion wasover filled hotATFwillspill from the fillerhole when the fillplug is removed ATF draining and filling The proceduregivenhereincludesremovaland installationof the fluid strainer filter Referto i...

Page 592: ...3 US qt without torque converter 6 1 liters 6 4 US qt A5S 5602 with torque converter 13 1 liters 13 8 US qt without torque converter 5 5 liters 5 8 US qt A5S 4402 with torque converter without torque...

Page 593: ...240 9 Automatic Transmission Automatic transmission fluid pan and strainer 1 ATF strainer 2 ATF strainer seal 3 Pan gasket 4 Sump magnet 5 ATFpan 6 Filler plug 7 Drain plug...

Page 594: ...e transmissionmay upset the balance of the vehicle on a lift CAUJION Tiltingthe engine to remove the transmissioncan lead to damaae to variouscomponents due to laclc of clearance 1 Transmission removi...

Page 595: ...ee 260 Driveshaft 4 With selector lever in park Hold linkage clamping bolt A stationary when loosening selector lever cable clamping nut 6 Loosencable clamping nut and removecablefrom bracket ASS 3252...

Page 596: ...tool 23 3 030 between engine oil pan and front subframe arrows 6 cylinder models Place BMW special tool 11 7 370 between engine oil pan and front subframe Support transmission with transmission jack...

Page 597: ...applicable Inspect engine drive plate flywheel for cracks or elongat ed holes Replace if necessary Be sure bellhousing alignment dowel sleeves are located correctly Replace damaged sleeves Checlc to b...

Page 598: ...grade 48 Nm 35 it lb MI0 10 9 grade 60 Nm 44 R lb MI2 8 8 grade 81 Nm 60 ft lb MI2 10 9 grade 100 Nm 74 ft lb MI4 140 Nm 103 it lb Torque converter to drive plate 45 Nm 33 ft lb flywheel MIO Transmis...

Page 599: ...anism adiustina automatic transmission 250 6 Manual Transmission Gearshift 250 3 Automatic shiftlock checking function Gearshift lever removing automatic transmission 250 7 manual transmission 250 3 S...

Page 600: ...immo bilizer EWS prevents starter operation unless the gear po sition is Park or Neutral Special tools BMW suggests the use of one specialtool inthe removal of the gear shift leverfor manual transmiss...

Page 601: ...underside of vehicle WARNING Male sure the car is stableandwellsupportedat all tfmes Useaprofessionalautomotwehftorjaclcstands designedfor the purpose A floorjaclc1 snotadequatesupport Removecomplete...

Page 602: ...ean shift console bowl Lubricate with molybdenum disulfide grease Insert shift lever together with inner boot and mounting ring into center console 4 Align shift lever mounting ring locking tabs with...

Page 603: ...ift ltnob on lever Tightening torque Driveshaft CV joint to final drive flange MI0 Tom bolt 70 Nm 51ft lb M8 compressionnut 32 Nm 24ft lb Driveshaft clamping sleeve MI0 ribbed nuts 80 Nm 59 ft lb MI0...

Page 604: ...automatic transmission Position gearshift lever in Park Raise vehicle to gain access to shift linkage WARNING Make sure the car isstable andwell supportedat all times Usea professionalautomotivelifto...

Page 605: ...al Without depressing bralte pedal check that selector lever is loclted in position Parlt or Neutral Depress brake pedal firmly Solenoid should click audibly Check that selector lever can now be moved...

Page 606: ...to the off position Remove ignition key Checlc that selector lever cannot be shifted out of Park position Turn ignition lkey on and depress brake pedal Checlc that selector lever moves freely from ge...

Page 607: ...sc replacing 260 11 Driveshaft description 260 3 Center bearing assembly replacing 260 12 Troubleshooting 260 3 Front centering guide replacing 260 13 Constant velocity CV joint replacing 260 14 Drive...

Page 608: ...pecial tools BMW suggests the use of certain special tools in removing installingor servicingthe driveshaftor its components 4 Transmissionjack Tool No BMW 00 2 030 4 Transmission support for use with...

Page 609: ...ionscan be transmittedthroughthedriveshaftto the car body Noisesfrom thecar may becaused byfinaldriveproblems or byfaultywheel bearings driveaxles or evenwom or improperlyinflatedtires NOTE For drive...

Page 610: ...veshaft section should be replaced Universaljoint play Maximumallowable 0 15 mm 0 006 in NOTE With the driveshaft installed the actualamount that the drive shaftjoint pivotsis limited For the most acc...

Page 611: ...driveshaft Check front centering guide and replace if necessary 40 to 50 kmlh mounting flanges out of round or damaged Check runout of driveshaft mounting flanges Universal joint worn or seized Check...

Page 612: ...ld be markedwith paint or a punch before proceedingwith work This will ensure that the drive shaft can be reassembledand installedinexactlythe original orientation 1 Rear section of drive shaft 2 Hex...

Page 613: ...ment loosen transmission or engine mounts to reposition them then retighten mounts The driveshaft should be exactly centered in driveshaft tun nel The second important driveshaft alignment check is mo...

Page 614: ...0 Exhaust System Remove exhaust heat shields Support transmission with transmission jack Loosen transmission mount nuts arrows on real transmission support crossmember Release wiring harness retainers...

Page 615: ...flange at groove A Hang driveshaft rear section from body using stiff wire Do not let driveshaft hang unsupported as rear CV joint rub ber boot arrow may be damaged 4 Remove center support bearing mou...

Page 616: ...ghten down remaining nuts I CAUTION I Donotreuseself lockingnuts Thesenutsaredesignedtobe I usedonlv once 1 Insert bolts in front of driveshafl to transmission output flange Counterhold each bolt whil...

Page 617: ...i2 8 8 grade 81 Nm 60 ft lb MI2 10 9 grade I00 Nm 74 ft lb MI4 140 Nm 103ft lb Transmissioncrossmember to transmission ME 21 Nm 15ft lb to chassis M10 42 Nm 30ft lb NOTE Boltgradeis markedon the bolth...

Page 618: ...60 Nm 44 ft lb Coatedwashers MI2 8 8 grade 5027500 Mi2 10 9 grade M14 81 Nm 60ft lb 100Nm 74ft lb 140 Nm 103 ft lb Install driveshaft as described earlier Center bearing assembly replacing The center...

Page 619: ...aft over the centering guide The dust cap may be come bent or distorted when the driveshaft is removedor in stalled Damage to the dust cap should not affect the centering guide andshould not be mistak...

Page 620: ...haft Check protective boot for damage Replace if necessary lnstall new CV joint Working from both sides of joint inject approximately 80 grams of OptimolB grease or equivalent into joint Install new s...

Page 621: ...agon EHC with air springs 300 8 EHC operational diagram 300 9 Steering 300 10 Rack and pinion steering 300 10 Recirculating ball and nut steering 300 10 Brake System 300 10 Wheels and Tires 300 11 Rim...

Page 622: ...th batteryacid Do not use wire brushes with brass or iron bristles Only use brushes with stainless steelbristles Do notexpose to flying sparks from grinding cuttingop erations Do not subject to steel...

Page 623: ...300 3 Suspension Steering and Brakes General Front suspension 6 cylinder models 5251 5281 530i...

Page 624: ...Suspension Steering and Brakes General Front suspension V 8 models 540i...

Page 625: ...edto the wheel bearing carrier through a pivotingintegral link An eccentric mounting bolt at the rear inner mounting of the swing arm is used for rear camber adjustment The inner end of the upper fron...

Page 626: ...ide is mounted between a perch at the top oi the wheel bearing carrier and the bottom of the cargo com partment floor Starting with 1999 SporlWagon models a self leveling air suspension system with el...

Page 627: ...Suspension Steering and Brakes General Rear suspension Sport Wagon with coil springs Shock absorber 1...

Page 628: ...rol sequence as necessary The system offers the following features Control system independent from vehicle engine no en gine driven hydraulic pump system Individual control of rear wheels Uneven load...

Page 629: ...EHC operational diagram LEFTAIR SPRING RIGHTAIR SPRlNG 50230000...

Page 630: ...0i I Recirculating ball and nut steering Recirculatingball and nutsteering in V 8 models consists of a steering box with integrated hydraulic control valve and con necting linkageto the road wheels Th...

Page 631: ...atured ABS with Auto matic Stability control ABSIASC Later models came equipped with ABS and Dynamic Stability Control ABSIDSC DSC builds upon the existing ABSIASC system to provide electronic control...

Page 632: ...each wheel to prevent wheel lock up Control moduleihydraulic unit in right rear of engine compartment No prechargepump Manuf from 911999 all models Automatic Stability Control ASC Dynamic Stability C...

Page 633: ...turned off iftheASC controlmod ule senses a difference in wheelspeed one wheelspinning the ASC system applies modulated braling force to the slip ping wheel until traction is regained There is no over...

Page 634: ...tion ABSIDSC control module OUI YIS 4 The DSC system can be toggledon and off by a switch mountedon the center console Turning off the DSC system does not disableABS or ASC functions Measure ride heig...

Page 635: ...mm 22 0 in 572 mm 22 5 in 587 mm 23 1 in 600 mm 23 6 in Maximumvariation betweensides 10 mm 0 4 in Maximum deviation from specifications 10 mm 0 4 in Standard suspension 579 mm 22 8 in 592 mm 23 3 in...

Page 636: ...0 in 588 mm 23 1 in l 573 mm 22 6 in 603 mm 23 7 in l 608 mm 23 9 in l 577 mm 22 7 in 560 mm 22 0 in Ride level control 562 mm 22 1 in 575 mm 22 6 in 590 mm 23 2 in 603 mm 23 7 in Sports suspension 53...

Page 637: ...gand installing Front Strut 310 4 8 models 310 13 Front strut assembly removing Tension strut removing and installing 310 16 and installing 310 5 Tension strut bushing replacing 310 18 Front strut ass...

Page 638: ...en sion components Thefoiiowing cautionsapply Due to the chemical and corrosion characteristics of aluminum do not bring into contact with battery acid Do not clean with wire brushes with brass or iro...

Page 639: ...Front Suspension Ball joint press Tool No BMW 31 2 240 Bushing press tools Tool No BMW 31 2 2611263 4 Spring compressor and spring holder arms 31 3 350 Tool No BMW 31 3 340 131 3 350...

Page 640: ...r arm 9 Center tie rod The front suspensionshoclc absorberson E39 cars are MacPhersonstruts The strut is a major componentof the front suspensionand supportsthe spring Most strut assem bly componentsa...

Page 641: ...ake hose See 340 Brakes Remove ABS pulse sensor mounting bolts arrows and re move sensor from housing DetachABS sensor wire harnessand braltepadwear sensor wire harness if equipped from strut housing...

Page 642: ...nt nota scribe tool to mark location ofstrut tube 1 4Letter on strut tube designates mounting location R Right side installation position L Left side installation position NOTE Marking the strut tube...

Page 643: ...If applicable disconnect plug connector at top of strut for Electronic Damper Control and remove cap from cable Remove upper strut bearing mounting fasteners arrows WARNING Do notremove centerstrut r...

Page 644: ...er of installation is reverse of removal Make sure strut shoulder below locator letter bottoms out in steering knuckle pinch collar Use new self locking nuts and bolts When attaching stabilizer lrnk t...

Page 645: ...ing pad 12 Coil spring 13 Rubber stop 14 Dustboot 15 Lower strut pad 16 Strut with lower springseat Front strut assembly disassembling and assembling Replacingthe strut upper strut mountor spring requ...

Page 646: ...ing holders arrows Compress spring WARNING When tensioned the spring coils must rest completely in thespring holder recess Never tighten or loosen spring compressor with an im pact tool Only tighten d...

Page 647: ...ut with impact tool NOTE illustration shows components for 6 cylinder models 5257 528i 5300 V 8 models 5400 are similar but not identical 4 Be sure upper and lower spring pads arrows are correctly ins...

Page 648: ...ushinas are availableas re lacement Darts Al ways replace in pairs NOTE Steering wheel vibration during braking usually at road speeds of50 to 60m p h are often causedby faultysuspen sion arm bushings...

Page 649: ...on Steering and Brakes Gen eral Bounce suspension a few times With car on ground and loaded tighten control arm bushing through bolt Tightening torques Control arm to steering ltnuckle 80Nm 59 ft lb C...

Page 650: ...ght Marking the strut tube is not necessary iffactory marks L or R are still visible CAUTION Usepaint nota scribe tool to mark locationofstrut tube Counterhold strut tube nut bolt arrow while loosenin...

Page 651: ...nut at this time lnstall control arm ball joint to steering knuckle using new self locking nut Tighten fully Slide strut back into position and tighten strut pinch bolt fully Install wheel and lower c...

Page 652: ...eld 6 cylinder models Remove brake cooling duct V 8 models Detach stabilizer bar from front subframe Mark installation position of strut tube arrow at steering ltnuckle pinch collar NOJE Thestrut tube...

Page 653: ...ean Install bushing end of tension strut to subframe using wash ers on both sides of bolt and a new self locking nut Do not tighten nut at this time Install tension strut ball joint to steering knuckl...

Page 654: ...outer steelsleeve duringinstallation Press bushing in so it protrudes equally from both sides of tension strut Install tension strut as described earlier CAUTION Tighten the tension strut bushingthro...

Page 655: ...Remove tie rod outer end nut Use BMW special tool 31 2 240 or equivalent to press tie rod end off steering arm 4 Mark installalion position of strut tube arrow at steering knuckle pinch collar NOTE T...

Page 656: ...steering ltnuckle pinch collar with BMW special tool 31 2 200 to release strut tube Pull steering knuckle down so that strut tube slides up far enough to gain access to wheel bearing hub mounting bol...

Page 657: ...e of dirt and grease Installation is reverse of removal Replace hub mounting bolts Use new self locking nuts at steering tie rod and stabilizer link Tightening torques Roadwheel lugs to hub 120i 10 Nm...

Page 658: ...s A from r glit and eft s des of slaol lzer bar C n I e r h o l ball olnl 6 with flat wrench NOTE Use a thin wrench to counterholdshaft of stabilizer bar link balljoint while removing mounting nut Rem...

Page 659: ...umn adjustment motors removing and installing 320 16 Power Steering Pump 320 17 Power steering pump removing and installing 320 1 7 Power steering system bleeding and filling 320 18 Rack and Pinion St...

Page 660: ...es in cluding the ignition switch see 612 Switches Special tools Some special tools are necessary to carry out the repairsand adjustments requiredfor steeringservice and wheel align ment Be sure to re...

Page 661: ...I Tool NO BMW 32 2 140 4Balljoint removaltool Tool No BMW 31 2 240 4 Ignition lock releasing tool Tool No BMW 32 3 110 4Steering column shear bolt Toot socket E8 Tool No BMW 32 3 120 4Camber setting...

Page 662: ...gear via an ad justable steering column which incorporates a rubber cou pling guibo to dampen vibration and noise Powersteering fluid is supplied from the fluid reservoir to the pump and to the steer...

Page 663: ...ion steering 1 Steering system variations I 6 linder rnodels 525i 28i 530i 1 Lefttie rod 2 Righttie rod 3 Steering rack 4 Steering gearbox 5 idler arm 6 Center tie rod 7 Steering knuckle Recirculatin...

Page 664: ...This will allow the reserve power supply to discharge Do not reuse self locking nuts They are designed to be used only once and may fail if reused Always re place them with new locliing nuts Do not i...

Page 665: ...nction MFL steering wheel Sport steering wheel 4 Multifunction MFL steering wheel components 1 Cruise control 1 radio 1telephone electrical harness 2 Horn button electrical harness 3 Airbag electrical...

Page 666: ...e of steering wheel Carefully lift airbag from steering wheel and disconnect elec trical harnesses from back side of unit Refer to component illustrations above Also see 721 Airbag System SRS Improper...

Page 667: ...derneath steering column disconnect electrical harnesses A and B Remove steering wheel When reinstalling steering wheel Align steering wheel and column match marks Align steering wheel to alignment pi...

Page 668: ...ngfor steering angle sensor 9 Upper support ringfor steering angle sensor 10 Steering angle sensor 11 Upper steering shafl 12 Steering shafl bearing 13 Bearing inner sleeve 14 Circlip 15 Collar 16 Ste...

Page 669: ...ling Remove upper and lower steering column trim as described earlier Disconnect electrical harness plug from ring antenna Useflat side of BMW special tool 61 3 300to pry ring antenna off ignition loc...

Page 670: ...oving and installing Disconnect negative cable from battery CAUTIO Prior to disconnectingthe battery readthe battery discon nection cautionsgiven in001 General Cautions and Warnings Remove steering wh...

Page 671: ...bolts can be drilledand then removed using an easy out Remove steering column lock housing Installation is reverse of removal Tighten new shear bolts until bolt heads shear off ignition interlock cab...

Page 672: ...down on interlock lever B andtighten cable mounting fastener A Steering column removing and installing Disconnect negative cable from battery CAUTIOI C Prior to disconnectingthe battea readthe battery...

Page 673: ...ng shear bolts Drill steering column mounting shear bolts arrow and use easy out to remove Remove upper steering column mounting bolts arrows Remove upper steering column Disconnect electrical harness...

Page 674: ...e same BMW scan tool CAUTION Checksteeringsystem for freedomofmovement throughen tire steering column adiustmentrange Tighteningtorques Steering shaft coupler to steering shaft 25 Nm 18 ft lb replaceb...

Page 675: ...de signedfor thepurpose Placejack stands beneathstructural chassis points Do notplacejack stands undersuspension Darts Removedrive belt from power steeringpump See 020 Main tenance Remove alternator c...

Page 676: ...pump banjobolts a M l O 12 Nm 9 ft lb M 1 4 35 Nm 26 ft lb M I 6 40 Nm 30 ft lb M I 8 45 Nm 33 ft lb Pump brackets to engine block 25 Nm 18 ft lb Rear pump support stud to pump housing 22 Nm 16 ft lb...

Page 677: ...izedfluid line 10 Steeringfluid cooler 11 Rack boot components 12 Tie rod nut 13 Washer 14 Outer tie rod end 15 Tie rod locking ring 16 Outer tie rodend loclc nut 17 Inner tie rod 18 Hydraulic control...

Page 678: ...om right steering Itnuckle Repeat for left 4 Press right tie rod out of right steering knucltle using BMW special tool 31 2 240 Repeat for left o c k nut Loclting ring 0012143 4Malte reference measure...

Page 679: ...d comDonents to reassemble steerino column flexible oint to teering raclt shaft u Use new bolt at steering shaft coupling Use new sealing O rings on banjo fittings Do not over torque banjo bolts Fill...

Page 680: ...LOCI nut Locking ring Raisefront of car Remove road wheel WARNING Malesurecaris firmlysuppoiiedonjackstands designedfor the purpose Placejack stands beneathstructuralchassis ooints Do notolace iacksta...

Page 681: ...Loosen and remove inner tie rod shafl from steering rackwith special tool 32 2 110 NOTE To avoiddamage tosteeringrack while removing tie rod turn steering untilendof rack is as far as possible inside...

Page 682: ...ing gearbox system components V 8 models up to 911999 1 Tie rod end nut 2 Washer 3 Tie rod end 4 Steering fluid cooler 5 Tie rod end clamp bolt 6 Nut 7 ldler arm 8 ldler arm bushing 9 ldler arm bolt 1...

Page 683: ...irbag with the hornpad facing up If stored lacing down accidentaldeploymentcouldpropel it violently info the air causing injuv Remove steering wheel as described earlier Drain power steering system re...

Page 684: ...te sure all thread bores bolts nuts splines and mating surfaces are clean 4 To install steering gearbox center steering column to gear box by aligning universal joint split with tab on steering gear b...

Page 685: ...to pitman arm using a new self locking Pilrnan nut arm 5nz3zn588 Connect harness connector for Servotronic electro hydraulic regulator if necessary Connect fluid hoses to steering gearbox Use new sea...

Page 686: ...th tab arrow aligned with mark on steering gearbox Remove center tie rod fastener and press tie rod out of pit man arm with BMW special too132 1 190 Loosen and remove pitman arm pinch bolt 4 Mark A on...

Page 687: ...standsbeneathstructural chassis points Do notplacejaclc stands undersuspension parts Remove bolts from left and right inner control arm mounts Place BMW special tool 32 2 140 through right side contro...

Page 688: ...purpose Placejack stands beneath structural chassispoints Do notplacejack stands undersuspension parts 4 Remove center tie rod fastener and press tie rod out of idler arm with BMW special tool 32 1 19...

Page 689: ...ess fittings 4 Press new bushing in correct direction arrow u A Press bushing in until lip makes firm contact A with idler arm I Installation is the reverse of removal Use new self locking nuts to mou...

Page 690: ...installed 4 Removeself loclting nuts connectingcenter tie rod to pitman and idler arms Press tie rod off pitman and idler arms using BMW special tool 32 1 190or equivalent 4 Loosen left tie rod clamp...

Page 691: ...y adjustable Always set rear camber before adjusting toe Before making rear camber adjustment install a new rear control arm mounting nut arrow and tighten Loosen mounting nut one half to one full tur...

Page 692: ...ut A Adjust toe by turning inner tie rod B to change length V 8 models Loosen left and right tie rod clamp bolts Adjust toe by turning inner tie rod to change length NOTE Steering rack or steeringgear...

Page 693: ...g and Brakes General Car is in normal loaded position See below Cars with air suspension Remove air suspension power fuse Normal loaded position Each front seat 68 Kg I50 lb Center of rear seat Trunlc...

Page 694: ...i 30 0 2 15 41 5 0 22 t 4 0 i 12 Geometrical axis deviation 6 55 i 30 0 i 15 41 5 0 22 i4 Total toe 0 22 i4 Camber difference between leitlright maximum 15 1 2004 5 1 2 04 i 5 O i12 Sport suspension P...

Page 695: ...Sport Wagon 540i O 10 iW lo 49 i 5 O i12 0 22 i 4 2 04 i 5 0 i 12 Parameter 1 43 i30 N I A 6 27 i 30 6 49 i30 P i l o 41 5 32 0 22 i4 2 04 i 5 O i 12 ID44 i 30 N A 6 34 i 30 6 50 130 0 i 15 42 31 8 S...

Page 696: ......

Page 697: ...ng sedan models 330 22 Upper rear control arm removing and installing Sport Wagon models 330 23 Upper front control arm tractionstrut removing and installing 330 25 Rear axle assembly removingand inst...

Page 698: ...tles Only use brushes with stainless steel bristles Do not expose to flying sparl s from grinding cutting op erations Do not subject to steel welding splashes 0 Do not expose to temperatures over 80...

Page 699: ...140 334148 334149 334151 334 155 33 4 156 4 Subirame mount tool set Tool No BMW334151 34140 334155 334154 4 Rear wheel bearing carrier mount tool set ToolNo BMW334151 334152 334153 334154 334 156 334...

Page 700: ...3 Finaldrive differential 4 Rear subframe 5 Upper rear control arm wishbone 6 Subframe mounting bushing 7 Drive axle 8 Upper front control arm traction strut 9 Swing arm lower control arm 10 Integral...

Page 701: ...seat back rest side sections See 520 Seats Fold down backrest Working inside trunk remove roller blind mountingnuts and bolts if applicable Also disconnect roller blind har ness connector at right ed...

Page 702: ...tallation of assembly to car is reverse of removal noting the following Make sure allthreaded bolts nuts and mating surfaces are clean Install strut assembly top mount using new self loclting nuts Mal...

Page 703: ...opera tion Do not use a spring compressor that is damaged Do not make any modifications to the spring compres sor Never use an impact wrench to compress or relieve tension when using a spring compres...

Page 704: ...eat I I Strut WARNING Malesure the upperself lockingnutis fully tightenedbefore releasingthe springcompressor Tighteningtorque Upper strut mount to strut shaft 27 Nm 20 ft lb M14 replace self locking...

Page 705: ...pose Placejack stands underneathstruc tural chassispoints Do not placejack stands under suspensionparts CAUTION If workingona vehicle withcompressedairshock absorbers disableair supply pump by disconn...

Page 706: ...ing torques Shock absorber to upper mount 27 Nm 20it lb M14 replace self lockingnut Installation on car is reverse of removal noting the following Make sure all threaded bolts nuts and mating surfaces...

Page 707: ...from mountingbracltetson sub frame Support final drive unit from below using transmission jack and BMW special tool 33 4 390 or equivalent Remove rear suspensionsubframe mounting bolts arrows Lower r...

Page 708: ...e system Remove luggage compartment floor mat Working above air spring loosen quick coupling screw con nection to allow air pressure to escape Once pressure has been reduced retighten screw Tightening...

Page 709: ...18 in lb Air spring to wheel bearingcarrier 20 Nm 15 ft lb Roadwheel to hub 120 510 Nm 89 F 7 ft lb REARSUSPENSION ARMS SUBFRAME AND BUSHINGS A damagedsuspensionarm orworn bushingswill changethe rear...

Page 710: ...ds de signed for the purpose Placejack stands underneathstruc tural chassispoints Do not placejack stands under sus ension Darts Disconnect control rod for ride height sensor if applicable Remove ABS...

Page 711: ...6 Installand tighten nuts finger tight Line up eccentric camber adjusting bolt with marlts made previously Tighten fasteners to final torque only after vehicle has been lowered and suspension has set...

Page 712: ...air springs Loosen compressedair pipes ar rows at air distribution assembly to release system pres sure NOJE Vehicle will stand quite low If applicable Detach air supply line from shock absorber Plug...

Page 713: ...ar rier Support wheel bearing carrier from below CAUTION The shockabsorberprevents the driveaxle and wheelbear ingcarrierfrom droppingtoo far Supportingthe wheelbear ingcarrier before disconnectingthe...

Page 714: ...ade previously Make sure long lower shock absorber bushing fits in hole in swing arm Tighten fasteners to final torque only afler vehicle has been lowered and suspension has settled Have car professio...

Page 715: ...the brake hose park ing brake cable and drive axle CVjoints Model with air shock absorbers Detach air supply line from shoclc absorber Plug ports and lines to keep out dirt Sport Wagon model Remove sh...

Page 716: ...33 2 301 between 2nd and 3rd spring coil from bottom Make sure tool recess faces upward Working incargo compartment guide BMW special tool 33 2 304from above and thread into special tool 33 2 301 Wor...

Page 717: ...nting bolt 1 from swing arm Pull swing arm down Remove integral link I swing arm metal bushing locating bolt 2 Remove integral link 4 Press bushing out of wheel bearing carrier using BMW spe cial tool...

Page 718: ...ehicle has been lowered and suspension has settled Tightening torques Integrallink to wheel bearingcarrier 105 Nm 77 ft lb Quick couplingscrew to air shock 2 Nm 18 in ib absorber Road wheel to hub 120...

Page 719: ...ib Control arm balljoint to wheel bearing 142 Nm 105 ft lb carrier M14 Quick coupling screw to air shock absorber 2 Nm 18 in lb Roadwheel to hub 120 flONm 89i7ft lb Upper rear control arm removing and...

Page 720: ...f spring seat on wheel bearing carrier 4 Models with air springs Loosen compressed air pipes ar rows at air distribution assembly to release system pres sure WARNING Vehicle will lower when the air pi...

Page 721: ...nsion swing arm Tighten fasteners to final torque only after vehicle has been lowered and suspension has settled Have car professionally aligned when job is complete Tightening torques Control arm to...

Page 722: ...rm tractionstrut to wheel 65 Nm 48 ft lb carrier Rear axle assembly removing and installing sedan models Incase of damage to the subframe or if a pressed in bushing isworn removesubframe by removing c...

Page 723: ...30 and 33 4 390 or equivalent NOTE Special tool 33 4 390 will needmodifications to cradle the ii nal drive properly 4 Remove right and left suspension trim panels arrow 4 Remove right and left lower s...

Page 724: ...S pulsesensor to wheel bearingcarrier 8 Nrn 6 ft lb Brake rotor to hub 16 Nm 12 ft lb DriveshaftCV joint to final drive flange MI0 Tow bolts 70 Nm 51 ft lb MB compressionnut 32 Nm 24 ft lb Rear brake...

Page 725: ...con nectingelectricalplugbeforeperforminganyrepairs Pumpis locatedbeneatha coverunderthesparetireinthe floorof the carqo compartment Models with air springs Loosen compressed air pipes ar rows at air...

Page 726: ...ition Install and t ghten sub frame mounting bolts Note that on each bolt rubber coat ed detent plate arrow must be installed at rear in driving direction Models w th coil springs Fit springs correctl...

Page 727: ...65 Nrn 48 ft lb bearing carrier Roadwheel to hub 120ilO Nrn 89 i 7 ft lb Rear subframe mounting bushings removing and installing Remove rear subframe mounting bolts as described earlier Lower subframe...

Page 728: ...lowered and sus oension has settled Rear wheel bearing carrier removing and installing sedan models Raise rear end of car and remove wheel WARNING Make sure the car is firmly supportedonjaclc stands d...

Page 729: ...ensor mounting fastener arrow and sensor 4 Remove outer swing arm nut arrow and bolt 4 Press out axle shaft using BMW special tools 33 2 117 3 3 2 1 1 6 a n d 3 3 2 l l l Support wheel bearingcarrier...

Page 730: ...ll axle shaft through wheel bearing car rier using BMW special tools 33 2 115 33 2 116 and 33 2 118 Lightly oil bearing surface of axle collar nut and install T ght en collar nut firmly but do not ful...

Page 731: ...earingcarrier 127 Nrn 94ft lb Road wheel to hub 120 10 Nm 89i 7 ft lb Swing arm to wheel bearing carrier 256 Nrn 189ft lb Upper front control arm tractionstrut to 65 Nrn 48ft lb wheel carrier Upper re...

Page 732: ...pushed down remove from inside coii spring from under car Working from underneath position BMW special tool 33 2 301 between 2nd and 3rd spring coii from bottom Make sure tooi recess faces upward Work...

Page 733: ...ow Remove brake caliper and brake disc Hang bralte caliper aside with stiff wire Do not disconnect brakefluid hose See 340 Brakes Disconnect parking brake cable from brake shoe expander See 340 Brakes...

Page 734: ...arrier assembly 4 When reinstalling pull axle shafl through wheel bearing car rier using BMW special tools 33 2 115 33 2 116 and 33 2 118 Lightly oil bearing surface of axle collar nut and install Tig...

Page 735: ...r spring to wheel bearingcarrier 20 Nm 15ft lb Brake rotor to hub 16 Nm 12it lb Rear axle shaft to hub M27 300 Nm 221ft lb Rearbrakepadcarrier caliper towheel 65 Nm 48ft lb bearingcarrier Road wheel t...

Page 736: ...s Leave brake hose connected to caliper Suspend caliper as sembly from chassis using stiff wire Remove ABS pulse sensor at wheel bearing carrier Remove drive flange from bearing assembly using impact...

Page 737: ...W special tools 33 2 115 33 2 116 and 33 2 118 or equivalent press tools to press wheel hub to bearing CAUTION BMWspecifiesspeclaltoolstopullthe wheelhubthroughthe wheelbearingintoposition Ifusingalte...

Page 738: ...at tached via stabilizer bar linltsto the lower swing arms Stabilizer bar removing and installing Raise rear end of car WARNING Make sure the car is firmly supported onjack stands de signedfor the pur...

Page 739: ...nk mounting nut arrow at stabilizer bar 4 Remove stabilizer link mounting nut arrow at swing arm Press out stabilizer link ball joints Installation is reverse of removal Tightening torques Stabilizerl...

Page 740: ...scriptionand sometroubleshootingis covered in300 Sus pension Steering and Brakes General Air spring replacement is covered earlier inthis chapter See Air spring removing and installing CAUTION Maintai...

Page 741: ...lectrical components cover A Release control module wiring harness plug loclting clip B and remove module Installationis reverse of removal After assembly reset ride height using BMW diagnostic scan t...

Page 742: ...A 45 in direction of arrow to remove Rotate electrical connector B 45 in direction of arrow to remove Compress wiring connector locking clips arrows and dis connect wiring harness Remove air supply u...

Page 743: ...Placejaclc stands underneathstruc turalchassispoints Do notplacejaclc stands under sus ension Darts Working underneath rear of car remove trim panel arrow just ahead of suspension subframe Disconnecte...

Page 744: ......

Page 745: ...alling sedan 331 14 Final Drive 331 5 Drive axle removing Final drive removing and installing 331 5 and SportWagon 331 15 Differential oil level checking 331 6 CV joint boots 331 17 Final drive i n u...

Page 746: ...manual Special tools BMW recommendssome special tools for the removalof the drive axles as well as the installationof rear differential input and output drive flange seals Some common pullersand drif...

Page 747: ...nt set ToolNo BMW334151 334152 334153 334154 3341551334156133415713341581334159 Differential mount press set Tool No BMW334161 1334162133416413341651 33 4 166 33 4 161 Q Differential mount press set T...

Page 748: ...seo If working with a umin m com ponents be sure to read and follow the cautions below CAUTIOI C Due to the chemicaland corrosioncharacteristicsof alumi num do not bring into contact with battery acid...

Page 749: ...ng stiff wire 4 Support final drive with BMW special tool 33 4 390 Remove front final drive mounting bolt Remove rear final drive mounting bolts 2 Carefully lower final drive unit To install use BMW s...

Page 750: ...nly a specially formulated synthetic gear oil SAF XO that is available through an authorized BMW dealer parts depart ment For additional information on this lubricant and any oth er lubricantsthat may...

Page 751: ...replacing Remove exhaust system See 180 Exhaust System Remove drive shaft See 260 Driveshaft Lift out collar nut locking plate arrow 4 While counterholding drive flange with special BMW tool 23 23 0...

Page 752: ...tools 31 2 101 31 2 102 31 2 103 and 31 2 104or equivalent Using BMW special tool 00 5 010 or equivalent remove seal from final drive housing 1 4 Drive new seal into place until its fully seated usin...

Page 753: ...viously marked points are aligned arrow CAUTION Donotunderanycircumstancestightencollarnutbeyondthe markedpoints othe lise clampingsleeve willhave to bere placed Using a suitable drift install new col...

Page 754: ...st system if necessary See 180 Exhaust System Remove drive axle CV joint bolts axle from body using stiff wire arrows Suspend drive 4 Drive out final drive output flange using soft faced hammer 4 Remo...

Page 755: ...lange splines en gage splines of differential gear and snap ring can be heard to snap into place Remainder of installation is reverse of removal Check and if necessary set differential oil level See D...

Page 756: ...e Differential oil level check ing Tightening torque Final drive cover to final drive housing M10 8 8 grade 45 Nm 33 ft lb M10 10 9 grade 90 Nm 66ft lb Final drive mounts replacing Remove final drive...

Page 757: ...ontact with rear axle carrier when top rubber mount is tightened down The slolled srde ot r11erubbermounlmustbe ar r ghl angles lorhegroovernspecalroo 33 1 165andshoulobe lrghrened I down ransversely...

Page 758: ...Reinforcement 10 Torx bolt Drive axle removing and installing sedan 4 With an assistant applying brakes break free staked collar nut arrow at center of rear wheel hub Do not remove com pletely NOTE T...

Page 759: ...rn 74ft lb Road wheel to hub 120 Nrn f 10 89ft lbf7 Drive axle removing and installing Sport Wagon 4 With an assistant applying brakes brealc free staked collar nut arrow at center of rear wheel hub D...

Page 760: ...cial tool 33 2 304from above and thread into special tool 33 2 301 4 Worlting in cargo compartment attach BMW special tools 33 2 302 332 303 and 33 2 305 to special tool 33 2 304 Use special tool 33 2...

Page 761: ...Nrn lO 89tt lbi 7 CV joint boots NOTE When replacinga CVjoint boot use a complete CVjoint boot repair kit The l i t will include a new boot clamping bands special lubricant and a new inner CVjoint cir...

Page 762: ...onto axle shaft Apply LoctiteO270 or an equivalent heavy duty loclting corn pound to drive axle splines Position new CV joint on shaft so that raised or taller side of hub is facing shaft WARNING Do...

Page 763: ...g and installing 340 20 Parking Brake 340 22 Parking brake components 340 22 Parking brake adjusting 340 22 Parking bralte shoes removing and installing 340 23 Parking brake cable replacing 340 24 ABS...

Page 764: ...and Brakes General Special Tools BMW requiresthe use of either the DIS or the MoDiCdiag nostictool to safely and completely bleedthe brak ng and tractioncontrol systems Readall proceduresthrough befo...

Page 765: ...10 4 Brake line flare wrench set 12 mm 14 mm 17 mm 19 rnm Tool No BMW 34 3 150 34 3 152 34 3 153 34 3 154 4 DSC Dressure sensor installationsocltet 4 ABS IASCor ABSI DSCcontrol unit42 pin harnessadapt...

Page 766: ...A summary of distinguishing characteristics of the various systems is shown in the table E39 electronic braking and stability control systems ForABS ASC and DSCsystem and component descriptions see 3...

Page 767: ...edal down hard with the engine running If the pedal slowly falls to the floor either the master cylinder is leaking internal ly or fluid is leakingexternally lnspect the rotors for glazing discolorati...

Page 768: ...bearings See 310 Front Suspension or33C Rear Suspension Check component installation Checldreplace anti rattle springs Checlt fluid level and inspect for signs of leakage Replace master cylinder Diag...

Page 769: ...self locliing fas teners CAUTlOI C Immediately clean bralie fluid spilled on painted surfaces and wash with water as bralie fluid will removepaint Always use new brake fluid from a fresh unopened con...

Page 770: ...nit Once air enters the hydraulic unit itis very difficult to remove usingtraditionalmethods Forthis reason pressurebrakebleedingshouldbe done inconjunctionwith the BMWSewice Tester DIS plus GTl MoDiC...

Page 771: ...n of arrow to remove Disconnect wiring harness from hood switch C Release filter body mounting clamp D and remove lower microfilter housing Top off bralte fluid in reservoir and connect BMW Service Te...

Page 772: ...DSC After BMW Service Tester bleeding rou tine has finished press brake pedal to floor 5 times until clear bubble free fluid runs out Close right front bleeder valve Models with ASC After BMW Service...

Page 773: ...bolts 2 Brake caliper 3 Brake padwear sensor 4 Brake padanti rattle clip 5 Brake pads 6 Front brake rotor retaining bolts 7 Front brake rotor 8 Rear brake rotor retainingbolt 9 Rear brake rotor 10 Par...

Page 774: ...aces with compressedair CAUTION Pressingcaliperpistonin may causebrake fluidreservoir to overflow T opreventthis usea cleansyringe to first remove some fluidfrom reservoir Raise car and removewheels W...

Page 775: ...ors as described lat er Bralte rotor specifications are given in table below Spread bralte pads using BMW special tool 34 1 050 or equivalent Remove brake pads CAU T I O G Pressingcaliperpistonsinmayc...

Page 776: ...g directional brake pads install the marked pads as shown NOTE BMW supplied OEM front brakepadsmaybemarkedas di rectionalpads Aftermarket brandsare generally not labeled as directional When installing...

Page 777: ...wheel to hub 120i 10 Nm 89i7ft lb Brake rotors removing and installing Raise car and remove wheels WARNING Male sure that the caris firmly supported onjack stands de signedfor the purpose Placejack s...

Page 778: ...6 in Front bralte pad carrler to steering ltnucitle 110 Nm 81 ft lb Rear 298 mm 11 73 in Rear brake padcarrier to wheel bearingcarrier 65 Nm 48 ft lb 20 4 mm 0 80 in 28 4 mm 1 12 in Roadwheel to hub 1...

Page 779: ...ngine compartment by releasing clips arrows 4Disconnect bralte fluid level sensor connector A from fluid reservoir Remove reservoir cap Using a clean syringe empty bralte fluid reservoir Where applica...

Page 780: ...using new sealing O ring and new self locking nuts CAUTIOI C Be sure to align mastercylinderpushrodandbooster pushrod Donotover torque master cylindermountingnuts This could damage the brake booster a...

Page 781: ...ommet 6 From 911998 Check valve in grommet in booster Remove left ventilation filter housing for access 7 To 911998 Check valve in vacuum hose Remove left ventilation filter housing peel back trim rub...

Page 782: ...A are equippedwithAntiloclc BrakingSystem ABS and eitherAutomatic Stability Control ASC or Dynamic Stability Control DSC In order for the bralchg and stability controls to workproperk if brake fluid l...

Page 783: ...g the following Make sure all nuts fluid couplings thread bores and mat ing surfaces are clean Replace bralte booster self lockingmounting nuts Replacesealing O ringbetweenmastercylinder and bralte bo...

Page 784: ...atedinto the I rearbrake rotors Itcan be adjustedwiththe wheels installed althoughthe rearwheels will haveto be raisedoffthe ground Adjusting the parking bralte becomes necessary under the following c...

Page 785: ...parking bralte warning light comes on if not adjust parking bralte warning light contact switch Install parking brake lever boot Install road wheel lug bolts Tightening torque Roadwheel to hub 120 i 1...

Page 786: ...orque Roadwheel to hub 120i lo Nm 89 i 7ft lb Parking brake cable replacing The parking brake is actuatedby two separate Bowdenca bles Each cable can be replacedseparately Working inside car gain acce...

Page 787: ...ow and detach from routing bracltets noting correct routing for rein stallation Remove parlting bralte shoes as described earlier 4 Pull shoe expander A forward disconnect parlting bralte cable B and...

Page 788: ...ontrol ABSI ASC Later models came equipped with ABS and Dynamic Stability Control ABS DSC This manual will refer to these systems as ABS ASC or DSC will be specified when necessary For ABS system and...

Page 789: ...neath or in front of driver s seat DSC system on 1999 and later cars Bosch DSC Ill v 5 7 Lateral acceleration sensor and rotational rate yaw sensor are combined into one unit located under driver ssea...

Page 790: ...perly a After replacing the sensor perform sensor adjustment using either DIS or MoDiC under Service Functions menu Tightening torques Lateralacceleration I rotationalrate sensor 8 Nm 6 R ib to bracke...

Page 791: ...quippedwith a DSC prechargepump mountedinthe engine compartment There is no separate prechargepump inthe Bosch DSC Ill v 5 7 system 1999models andlater WARNING E39carsrequirespecialBMWserviceequipment...

Page 792: ...SCpressuresensor isnotrecommendedunlessthisequipmentisavailable For safetyreasons thebrakesystemoncarswithABS mustbe bledusingtheproceduresdescribedin this repairgroup Switch off ignition andremovekey...

Page 793: ...in memory Install electroniccontrol unit using new screws Tightening torque DSC electroniccontrol unit to 2 9 Nrn 26 in lb hydraulic unit use new screws Code newly installed module using either DIS or...

Page 794: ...efully push aside brake lines from retainerslgrommets that may be inthe way of hydraulic unit removal Use care not to kink brake lines Remove hydraulic unit mountingscrews Remove hydraulic unit If nec...

Page 795: ...gate lock system 400 5 Rear wiper system 400 6 Antenna and sound system 400 6 Safety and Security Features 400 7 Safety cage 400 7 Door locks and door handles 400 7 Seat belts 400 7 Airbags 400 8 Batt...

Page 796: ...400 2 Body General This chaptercoverssystem descriptions and generalinfor mation for the repair groups found insections4 Body and 5 Body Equipment Body dimensions in inches E39 sedan E39 Sport Wagon...

Page 797: ...aided design CAD techniques have been used in refiningthe E39body to reduce vehicle weight while retaining strength and increasing torsional rigidity For good handling purposes the more rigid the str...

Page 798: ...gons are available intwo vari ants 6 cylinder 5251 528i powered by the 2 8 liter M52TU en gine 1999 or the 2 5 liter M54 engine 2000 and later V 8 540i powered by the 4 4 liter M62TU engine The wheelb...

Page 799: ...ZV Iteylessentry control 4 An emergency release mechanism is incorporated into the latch assembly to open the hatch from the vehicle interior if a malfunction occurs The tailgate lock assembly include...

Page 800: ...med rear window wiping interval Operation of rear window washer The wiper system automaticallycontrolsthe following safety and conveniencefeatures Wiper interrupted when rear glass is opened Wiper int...

Page 801: ...ty and security against theft Door position and loclc condition are detected by hallsensors Roof padding In addition to the side and headprotection airbags there is supplementary paddingat the roof pi...

Page 802: ...gn including a sensorto helppreventthe unneces sary deploymentof the passengerside airbagifthe seatis un occupied MRS control Depend ng on options chosen one airbag may be installedin module each door...

Page 803: ...ess the correct coded ignition key is used NOTE Electronic immobilization is sometimes referred to as the driveaway protection system Antitheft alarm DWA This isadealer installed optionfor which the E...

Page 804: ...inates with outside mirror memory These functions are controlled by the seat mem ory module s For security reasons the release lever to fold the rear seat backrest forward is installed in the trunk Sp...

Page 805: ...dditionto dis playingnavigationsystem information this monitoraccesses On BoardComputerfunctions audiosystemcontrols mobile phone dialling and memory andautomatic ventilation Park Distance Control PDC...

Page 806: ...n extra large infinitelyvariable radial blower motor for good distributionof air Freshair enters through the grille be low the engine hoodand intothe passengercompartmentvia the dashboard and footwell...

Page 807: ...Special tools 410 2 Hood raising to service position 410 6 Hood removing and installing 410 7 Front Fenders 410 2 Hood aligning 410 8 Front fender removingand installing 410 2 Hood latch components 4...

Page 808: ...e tools Some BMW special tools are required to set body pieces into the service positions Front fender removing and installing Raise front of vehicle and remove wheel WARNING Make sure that the car is...

Page 809: ...e headlight trim panel locking clip with a screwdrivel arrow Working at corner of side trim panel pull trim panel out from side of fender to remove Remove front bumper See 510 Exterior Trim Bumpers Wo...

Page 810: ...rch fastener ar row With door open remove fastener fender to door post arrow attaching upper Remove screw arrow at front of fender Remove ground strap nut and hood hinge bolts arrows CAUTION Securehoo...

Page 811: ...Installation is reverse of removal noting the following Before installing new fender clean old sealant and protec tive coating from mounting surfaces Position new fender and loosely install all mounti...

Page 812: ...icalComponent Locations The hoodisheavy Beforeremovingthehoodsupports be sure to have an assistant help support the hood Open hoodfully With the help of a partner supporthoodand remove retainingclips...

Page 813: ...n of hinge plates With the help of a assistant support hoodand removeretain ing clips A on upper end of pressurizedlifting struts Pull struts off hood Loosen upper hinge bolts B Remove lower hinge bol...

Page 814: ...p paint The hoodshould be aligned so that gap arrows to fender is as even as possible 4 If height adjustment at rear of hood is off adjust height using adjusting screw in lower hinge arrow Loosen and...

Page 815: ...the compressed rubber tape Using measurement dimension adjust detent buffer A Hood should be under a slight preload 0 5 mm Fellow the same procedure on the front buffers B After adjustmenthavebeen ma...

Page 816: ...ized Strut 3 Spacer 4 Hinge 5 Ground stud 6 Torx bolt 7 Torx bolt 8 Hex bolt 9 Bowden cable bracket 10 Ball pin 11 Torx bolt 12 Spring pin 13 Stop buffer 14 Bowden cable 15 Lower hood lock 16 Bowden c...

Page 817: ...fully latch hood several times so pins on hood center themselves in lower loclts NOTE Do not let hoodlock with latch bolts loose Tighten hood spring pin bolts and latch bolts when alignment is correct...

Page 818: ......

Page 819: ...ge adjustment 411 5 Door hinge assembly 411 6 Doors 411 2 Front or rear door removing Door Panels 411 7 and installing 411 2 Door trim panel removing and installing 411 7 Door check replacing 411 4 Si...

Page 820: ...515 Central Locking and Anti Theft WARNING E39 carsare fitted withside impactairbagsin the frontdoors and optionalside impact airbags in the rear doors When servicing doors always disconnect the negat...

Page 821: ...sure noloadisplacedon wirinq harness Installation is reverse of removal Keep in mind the following Mount and align rear doors first followed by the front doors Align door so that panel gaps are equal...

Page 822: ...airbags in the rear doors When servicing doors always disconnect the negative battery terminal See 721 Airbag System SRS for cautionsand procedures relating to the airbag system Close door window comp...

Page 823: ...when reinstalling side impact airbag to door Tightening torque Door check to door frame 24 Nm 16 it lb Door hinge adjustment If the installed door is uneven or out of parallel spacers can be usedto c...

Page 824: ...1Doors Door hinge assembly 1 Door 2 Spacer ring 3 Upper hinge 4 Hex bolt 5 Spacer ring 6 Lower hinge 7 Door check gasket 8 Doorcheck 9 Pin 10 Torx bolt 11 Gasket 12 Cover...

Page 825: ...721 Airbag System SRS for cautions and procedures relating to the airbag system Door trim panel removing and installing Disconnect negative battery cable CAUTION Prior to disconnecting the battem rea...

Page 826: ...411 8 Doors Pry off plastic plug arrow from door handletrim and remove screw 4 Carefully pry out window switch panel and disconnect elec trical harness plugs Slide door handle through trim panel...

Page 827: ...stalling door trim panel replace any damaged plas tic clips arrows NOTE Yellow door trim clips white arrows at front are longer than white door trim clips blaclc arrows 4 Checlt if support clip for do...

Page 828: ...pry up door sill trim Starting at A pil lar press radius of trim downwards while sliding trim forward off trim clips Remove clips from body using pliers Save for installation Installation is reverse...

Page 829: ...lgate Sport Wagon Models Tailgate emergency release Tailgate and window strut diagram Window strut removal diagram 412 8 Rear window gas strut removing and installing 412 9 Tailgate gas strut removing...

Page 830: ...s paintedat the factory after assembly Realign ment of bodypanels may expose unpaintedmetal Paint all exposed metal once the work is complete Trunk lid removing and installing 4 Raise trunlc lid Open...

Page 831: ...rness by pulling through opening in lid frame D While supporting trunk lid loosen left and right top hinge fas teners arrow A and remove lower fasteners arrow B NOTE Before loosening hinge bolts mark...

Page 832: ...should be mounted flush with body side panels arrows Lid fit toler ance is rt 1 mm 0 04 in Raise trunlc lid and support in open position Turn trunk lid detent buffers in 4 Remove trunlc strut retainin...

Page 833: ...ap is 0 5 mm 0 02 in Adjust to fit side body panels Open trunlc lid Be careful not to alter adjustments Tighten lower trunlc lock fasteners Close trunk lid and check adjustments Repeat process if nece...

Page 834: ...retaining clips damaged during removal Tailgate emergency release The tailgate of the E39 Sport Wagon has no ltey cylinder An emergency release mechanism is incorporated into the tail gate latch This...

Page 835: ...r Trunk Lid Tailgate Tailgate and window strut diagram 1 Rear window frame 2 Gas struts for tailgate 3 Gas struts for rear window 4 Rear window frame...

Page 836: ...Lid Tailgate Window strut removal diagram 1 Rear window 2 Rear window gas strut 3 Inner strut support 4 Tailgate gas strut 5 Area to install protective tape 6 BMW specialtool 51 2 153 7 BMW special t...

Page 837: ...and willclose withoutbothpressu rizedliftingstruts installed Properlysupporttailgateprior to removalof the liftingstruts Remove fasteners A from rear window hinge trim cover While pressingdetents A an...

Page 838: ...upport tailgafeprior to r1removalofthe lifting struts Working at hinge end of strut removestrut retainingclip and remove strut from mounting pin Slide BMW special tool 51 2 152over strut until end of...

Page 839: ...pecial tool 51 2 151 must be chamferedin area A Press tool down to release inner end of gas strut Push strut forward and toward center of vehicle to remove When installing strut make sure ball cup is...

Page 840: ...ndow frame Lower tailgate so that hinge for tailgate and rear window can be tilted Tilthinge for tailgate and rear window frame so that tailgate can be moved towards the rear with rear window frame Re...

Page 841: ...body last Height of spoiler is set by alignment of the rear tailgate Gap of spoiler to body is set by adjusting spoiler attach ment fasteners Lateral and vertical alignment of the window and tailgate...

Page 842: ...ght lateralguideto bodyfasteners arrows until guide can be moved 4 Loosen left and right tailgate lateral guide fasteners arrow and fully retract guides Check fulcrum pads arrows on lower section of t...

Page 843: ...unloclcingfixture of up per section of tailgate loclc For this reason the cable connections to the upper section of the tailgate loclc must remain connected Othe tise the tailgate can only be opened...

Page 844: ...the tailgate adjust ment at each marked point Adjust gap dimensions in accordance with adjustment spec ifications B C D E and F 4 Adjustment B a 11 0 5 mm 0 04 in 0 02 in b 1 mm 11 0 5 mm 0 04 in1 0...

Page 845: ...nrnil rnrn 0 05ini0 04in 2 rear side panel b 4 5 rnrn 11 0 5 rnrn 0 18 in 0 041 0 02 in 4 Adjustment F a 1 3 rnrn 2 1 rnrn 0 05 in 20 04 in b 1 rnrn20 5 rnrn 0 04 i0 02 in c 1 3rnrn lrnrn 1 3rnrn 0 05...

Page 846: ...e posi tion of the rear window frame changes with respectto the tailgate Always check the settings of the rear window frame to the tailgate and make adjustment if necessary NOTE The tailgate should be...

Page 847: ...g care not to change hinge posi tions 4 Tighten lower tailgate hinge fasteners arrows Reconnect eccentric pin actuator motor electrical harness Plug CAUTION Theeccentricpininthelowersectionofthetailga...

Page 848: ...ust height of upper section of tailgate lock loosen fas teners move upper section of lock and retighten fasteners Repeat contact pattern test after height adjustment Tailgate lateral guide adjusting I...

Page 849: ...itionarea betweenrooflailgate tailgatemustnotex tendabove heightofroof othe lise windnoise willbe creat ed If necessary adjust height of rear window frame by inserting spacers between the hinge and th...

Page 850: ...iingpin and the rotary latch in the lower section of lock Open tailgate and tighten lower loclc assembly fasteners Be careful not to alter inclinationof loclting pin B when tighten ing loclc nut A 4 T...

Page 851: ...lding replacing 510 13 510 2 Radiator grill removingand installing 510 14 Headlight housingtrim panel 510 3 removingand installing 510 14 removing and installing 510 4 Bumpers 510 5 Front bumper assem...

Page 852: ...de mirror glass replacing CAUTIOI C Mirrorshouldbeatoraboveroomtemperaturebeforeremov al Othe lise smallplasticparfs or glass maybreak Outside mirror glass without automatic dip control replacing Inse...

Page 853: ...ingelement har ness connectors from back of mirror glass 4 Installmirrorglass by placingglass on lugs arrows andturn loclting pin until glass is locked in place Outside mirror housing removing and ins...

Page 854: ...k mirror function before installing covering parts Outside mirror assembly removing and installing Remove front door panel trim See 411Doors 4 Carefully lift inner trim panel up to remove from retaini...

Page 855: ...llation is reverse of removal NOTE Checlt mirror function before installing covering parts Tightening torque Outside mirror to door M6 6 Nm 4 5 It lb BUMPERS Raise and properly support vehicle WARNING...

Page 856: ...ront bumper assembly 1 Bumper support shock absorber 2 Bumpersupport shock absorberseal 3 Bumper mounting bolt 4 Bumpersupport 5 Bumperto body gasket 6 Bumpercover 7 Grill panel 8 Lower bumper grill 9...

Page 857: ...neath car Remove expansion rivets arrows from lefl and right side trim panels Remove bumper trim panels 4 Remove driving light mounting fasteners arrows and dis connect wiring connectors 4 Worlting at...

Page 858: ...Tightening torque Bumperto impact absorber M10 41 Nm 30ft lb Front bumper impact absorber replacing To access front bumper mountingbracketand impact absorb er mountinghardware removefront bumper cove...

Page 859: ...J3umpers Rear bumper assembly 1 Center trim cover 2 Side trim cover 3 Bumper cover 4 Bumper support 5 Outer support guide 6 Innersupport guide 7 Bumpershock absorberseal 8 Bumpershock absorber 9 Bumpe...

Page 860: ...rrows Working in luggage compartment Raise spare tire cover Remove trim panel covering luggage compartment latch Open battery cover trim panel on right side and luggage compartment Open left side trim...

Page 861: ...ar rows and adjust height Tighteningtorques Impact absorber to chassis ME nut 20 Nm 15 ft lb Side bracket to body 6 Nm 53 in it Rear bumper impact absorber replacing Raise and properly support vehicl...

Page 862: ...ignedfor the purpose Place thejack stands beneatha structural chassispoint Donotplacejack stands undersus pensionparts 4 Using a 12 inch extension and a 14 mm Allen socket turn ad justing collar clocl...

Page 863: ...with tape CAUTION Protecthoodpaintby coveringarea aroundemblem with tape 4 Pry up emblem carefully on either side arrows NOTE Notice tape on screwdriver tips Installation is reverse of removal Replac...

Page 864: ...g Before installation assemble chrome trim ring and grill insert securely Replace components if tabs or catches are brolten or missing Install grill andtrim ring in appropriate location in hood Press...

Page 865: ...nti trap strip removing 512 7 Rear window child lockout switch 512 3 Door window adjusting 512 8 Power window motors 512 4 Door window removing and installing 512 9 Convenience openinglclosing 512 4 W...

Page 866: ...indow motors is carried out directly by the General Module GM Ill One touch operation in both directions on all four windows Cable type window regulator used for all door windows Anti trap protection...

Page 867: ...ions two each for the standard mode of operation and two for the one touch mode All window oper ation signals are digital inputs to the door modules and GM 1 1 1 The switch functions in the same manne...

Page 868: ...function is deacti vated and a fault code is stored Window anti trap protection 4 A rubber pressure guard is located at the top edge of each door frame It consists of two contact strips that close whe...

Page 869: ...ith brolen glass If a window is brolen all of the glass bits should be vacuumed out of the door cavity Usea blunt so ewdi iv er to clean out any remaining glass pieces from the window guide rails When...

Page 870: ...ndow should contact block then immediately reverse direction and lower by approximately 25 mm 1 in NOTE Anti trap strip is integrated into the molding strip of the door window frame Front window anti...

Page 871: ...er cover 4 Foam insulation After installation recheck anti trap protection Rear window anti trap strip removing Remove rear door panel and vapor barrier as described in 411 Doors 4 Remove window frame...

Page 872: ...oor panel as described in 411 Doors Disconnect negative cable from battery Remove airbag unit and vapor barrier from door See 721 Airbag System SRS WARNING Prior to disconnectingthe batteg readthe bat...

Page 873: ...Front window gap settings Front of window A 5 4 mm 0 21 in Top of window 6 10 mm 0 39 in Tightening torque Window regulatorguide railto door 10 Nm 89in lb Door window removing and installing Remove d...

Page 874: ...ng carefully with a plastic prying tool remove window trim strip from door Starting from rear of inner window trim strip carefully on trim strip clips arrows to remove window trim Loosen 1 clamping ja...

Page 875: ...impact airbags always disconnect the negative battery cable See 721 Airbag System SRS for cau tionsand procedures relating to the airbagsystem Prior to disconnecting the battery read the battery dis c...

Page 876: ...ners arrows Remove window regulator fasteners arrows Loosen fasteners arrows and slide regulator up to remove from mounts Remove window regulatorthroughopening in bottom of door checking for any wirin...

Page 877: ...oor window removing and installing Do not remove window from door Push window up and use wedge to hold in position Loosen fastener arrow and slide window regulator up and out of mount Disconnect wirin...

Page 878: ......

Page 879: ...h Panel 513 7 Lower dash panel assembly removing and installing 513 7 Upper dash assembly removing and installing 513 11 Window and door post trim panels removingand installing 513 12 Dash panel suppo...

Page 880: ...system serviceis attemptedbypersons un familiar with the BMW SRS and its approved service procedures BMW speciiies that all inspectionand service should be performed by an authorized BMW dealer Before...

Page 881: ...the emergency brake cable ends NOTE The accompanyingphotos illustrate a model with automatic transmission Manual transmissionmodels are similar Center console removing and installing 4 Remove shift kn...

Page 882: ...holder arrow out of console 4 Pry air vent down to release locking clips and remove Remove screws arrows at base of front seat armrest and slide armrest forward to remove 4 Remove console glove box A...

Page 883: ...her switch A Disconnect wiring harness B Remove trim panel fastener arrow under 4 way flasher switch 4 Remove console trim panel retaining fasteners arrow at rear of trim panel Remove front console tr...

Page 884: ...d handle forward off brake lever Remove parking bralte cover fastener arrow and remove cover 4 Remove fasteners at rear of console arrows 4 With left and right seats in lowest position remove side con...

Page 885: ...and installing Disconnect negative cable from battery and cover termi nal with insulating material 7 CAUTION Prior to disconnectingthe battery readthe battery discon nectioncautionsgiven attheirontin...

Page 886: ...1 mm and turn through 90 Disconnect wiring harnesses from radio Remove radio 4 Remove left and right locking clips arrow from glove com partment straps 4 Carefully pry left and right dashboard trim ou...

Page 887: ...pen glove compartment door Remove right side foot well trim panel screw and slide rim panel back to remove 4 Remove glove compartment mountingscrew from right side of dash arrow Remove right side cons...

Page 888: ...de lower dash fastener arrow 4 Remove upper dash fastener arrow Pull bottom of lower dash out to remove Installation is reverse of removal noting the following Instrumentcluster harness connector locl...

Page 889: ...and installing I I 4 Remove instrument cluster fasteners arrows and swing cluster out to remove Disconnectwiring harnessesfrom instrument cluster 4 RemoveA pillar windshieldpillar trim on left and ri...

Page 890: ...l Window and door post trim panels removing and installing Windshield posttrim A pillar removing and Installing On 1998and later cars disconnect battery negative cable I WARNING On 1998andlatermodels...

Page 891: ...sary replace defective or broken mounting clips Door post trim panel B pillar removing and installing 4 Remove seat belt fastener arrow from seat frame Remove front and rear door sill trim panels Pull...

Page 892: ...Sairbags 1 I WARNING On 1998andlatermodels rearHeadProtectionSystem HPS airbagsmaybe installed optional equipment in the driverandpassengersideC pillararea Theproceduregiven belowdoes notcovermodels w...

Page 893: ...rear HeadProtectionSystem HPS airbags maybe installed optionalequipment The proceduregivenbelowdoes notcovermodels with rearHPS airbags See721 Airbag System SRS Remove C pillar trim panels See Rear w...

Page 894: ...l and right side mounting clips arrow and support straps Close glove compartment Remove right side lower dash panel 4 Working under right side of dash removeglove compartment hinge fasteners arrows Wh...

Page 895: ...Locks 515 16 Door handle outer removing and installing 515 16 Door latch removing and installing 515 17 Outer door lock cylinder removing and installing 515 18 Trunk Lock Assembly 515 19 Trunk lock re...

Page 896: ...ocks trunk or tailgate lock andfuel filler flap lock The control module for the Central Body Electronics system ZKE Ill lknown as the General Module GM Ill controls central locking ZKE Ill manages the...

Page 897: ...515 3 Central Lockingand nti heft Central locking inputs and outputs iBzi ilziPobi lic u uin Ai Rnl irRum...

Page 898: ...r the first unloclcrequestwillonly unlockthe driver sdoor A second unlock request will unlock the remaining doors trunk or tail gate andfuel flap Trunk locking I The vehicle can be locked unlocked fro...

Page 899: ...the vehicle where the ltey can mechanicallycontrol all of the cen tral locking system functions 4 Door key positions for electrical manual loclting and unlocking are 1 Manual unlock 2 Unlock DWA disar...

Page 900: ...ral lock switch is pressed to single loclc the vehicle The loclc mechanism isfully locked at this point but can stil be openeo fromthe interor by pulng the appropri are interior door nandle lwce or by...

Page 901: ...s entry system FZV uses a tiny ra dio transmitter in the vehicle key to lock and unlock the doors and the trunk by remote control There are a number of other features incorporated in FZV Locltinglunlo...

Page 902: ...a K Bus Locking and unlock ing of doors trunk or tailgate and convenience closing is car ried out by the GM subsystem controlling the door lock window and sunroof modules The accompanying schematic Re...

Page 903: ...Button3 press and hold Panic mode alarm LED 4 providesfeedback of system operationand battery condition LED is eliminatedfrom 2000 and later lkeys LEDflashes indicatethe following One flash indicates...

Page 904: ...uminate an instrument cluster message 502515092 J NOJE If batteries are replaced within one minute of removal it is not necessary to periorm initialization Tlie state of charge of key batteries has no...

Page 905: ...gnedcorrectly Always initialize the keys in the same order es momentarily Release both buttons GM immediately locks and unlocits doors to signal successful initialization Remote system coding Initiali...

Page 906: ...by a s gnal from the keyless entry system FZV Car Memoryand Key Memory are actually two separate func tions although they are marketed as a combinedfeature Car Memory Pr or ro new veh c ede very the B...

Page 907: ...Key Memory functions vary basedonvehicle equip ment The functions that can be set include Automatic locking after start off vehicle speed Selective locking Heating 1AJC blower speed heated or cooled a...

Page 908: ...GM when trunlc has re leased Actuator shuts off When closing trunk third microswitch on trunk latch sig nals GM to activate actuator Cam turns to pull lid closed Foroverloadprotection ONduration of a...

Page 909: ...tch on the interior lightswith a tailgate unlock request The rearwindow is openedwith the releaseswitch onthe rear wiper arm cover Pressingthe switch signals the GM to acti vate the rear window releas...

Page 910: ...he door edge Close window on front door Disconnect battery negative cable CAUTlOG Prior to disconnectingthe batter readthe battery discon nectioncautionsgiven in001 General Warnings and Cau tions Remo...

Page 911: ...ions Remove door trim panel See 411 Doors Remove air bag See 721 Airbag System SRS Remove outer door handle See Door handle outer re moving and installing Working inside door cavity release loclting t...

Page 912: ...ng in latch mechanism in set Remainder of installation is reverseof removal Operate loclc using key before installing door trim panel Tightening torques Airbag to door replacescrews 8 5 Nm 75 in lb Ou...

Page 913: ...al Tightening torques Airbag to door replace screws 8 5 Nm 75 in lb Trunk lock removing and installing Remove plastic trim panel Remove screw cap and screw A Remove expansion rivets B Gently pry out m...

Page 914: ...atch fasteners arrows Remove latch and disconnect wiring harness Installation is reverse of removal Trunk lock striker plate removing and installing 4 Remove left and right trim panel fasteners arrow...

Page 915: ...e equippedwith a passive theft preventionsys tem The ElectronicImmobilizationSystem EWS makes it impossibleto startthe engine usingany meansother than the special lkeys furnished with the vehicle NOTE...

Page 916: ...ling antenna surroundsignitionswitch I System designation EWS II I I l ransmitter I receiver module located in right side steering column cover I E39 production dates SOP 311997 I I IEWS 111 3 2 contr...

Page 917: ...plug module and remove from holder Installation is reverse of removal Transmitter receiver module Only EWS IIvehicles are equipped with a separate transmit ter receiver module attached to the steering...

Page 918: ...obilizer EWS is also activated when DWA is activated The alarm isswitched off immediately if key is inserted in door loclt or FZV key button is used DWA LED Status The DWA status LED is located in the...

Page 919: ...r the sensor must be installed in the correct direction to ensure proper operation of the system lnterior sensor FIS 1997 1999 models 4 When the alarm system is armed the FIS sensor emits elec tromagn...

Page 920: ...inconsistent the UIS deter mines motion in the interior compartment If motion is detected the UIS changes to a constant cycle and the echo is compared again If the inconsistency is still present the U...

Page 921: ...0 2 Rear seat cushion and backrest Seat memory position setting 520 2 removing and installing sedan only 520 7 Headrest removing and installing 520 8 Front Seats 520 4 Seat switch and memory module re...

Page 922: ...iag nostics Seat memory position setting With the transmission range selector in P and the mirror change over switched in the left position switch the ignition on and press the M on the memory switch...

Page 923: ...column adjustment switch 3 Seat memory module with adjustment switches 4 Headrestmotor 5 Backrest motor 6 Seat base tilt angle motor 7 Seat base up down motor 8 Seat forward back motor 9 Steering colu...

Page 924: ...injury BMW recommends that all repair or replacement worlc on pyrotechnic devices must be carried out by a quali fied BMW technician Be sure to disconnect the battery and wait 5 seconds before attempt...

Page 925: ...and installing Turn ignition switch to OFF position Removefront and rear rail trim panels Raise center of trim panel A to release loclting pin Unlock and lift out inner mounting clips tabs 6 Slide tri...

Page 926: ...1Seats 4 Remove fasteners arrows from rear Move seat as far back as possible of seat rails 4 Open seat electrical harness cover A to release plug loclc 6 and disconnect electrical connector C...

Page 927: ...equivalent means to keep seat harness wiring from fraying Tightening torques Front seat to floor 42 Nm 31 ft lb Seat belt end to seat frame 48 Nm 35 ft lb E39 models are equipped with at least three d...

Page 928: ...E Ifthe carisequippedwithheatedrearseats detach electrical harness connector s as you remove the seat components 4 When reinstalling be sure to pull seat belts and buckles ar rows up through appropria...

Page 929: ...540 3 Sunroof panel emergency closing 540 4 Sunroof adiustino 540 5 unroofwitil steel roof panel adjusting 540 5 Sunroof with glass roof panel adjusting 540 7 Sunroof Components 540 8 Sunroof componen...

Page 930: ...This provides cabin ventilation with lesswind noise A water channel is incorporated into the sunroof assembly It automatically rises when the sunroof panel is in the vent posi tion and prevents water...

Page 931: ...ly during operation After normalization open and close sunroof once by pressing switch NOTE Inthe event of a faulty triggering of the anti trap protection in a specific position the fault can be recti...

Page 932: ...hrough light opening and pressing down 4 Disconnect electrical connections arrow and lay switch panel aside 4 Insert hex ltey into drive in sunroof motor arrow and turn hex ltey to manually close sunr...

Page 933: ...e flush to 1mm 0 04in below sur face of roof Rear of sunroof must be flush to 1 mm 0 04 above sur face of roof NOTE Use a creditcardto measure the gap The cardsllouldinsert throughthegap withequalresi...

Page 934: ...forward and tighten wedge nuts 6 Tighten center nut A 4 Adjusting front roof height Loosen lefl and right fasteners A Set front of sunroof to ideal height by moving panel up or down Tighten fasteners...

Page 935: ...from lower edge of sliding mechanism With gaiters removed three adjusting screws are visible at front and rear of panel 4 Sunroof panel is retained by three Torx screws arrows on each side To adjust s...

Page 936: ...Sunroof comDonents 1 Left rubber boot suppori 2 Left upper control rail 3 Leftside water channel repair ltit 4 Left lower control rail 5 Left cover 6 Left side slider 7 Cross member 8 Sunroof frame 9...

Page 937: ...r glass Remove sunroof panei See Sunroof panei removing and installing steel or glass Pull old seal from panel Coat new seal and channel in sunroof panel with soapy water Starting at back center of pa...

Page 938: ...lfrom below sunroof motor by inserting fingers through light opening and pressing down 4 Remove sunroof motor mounting screws arrows Installation is the reverse of removal Perform initialization proce...

Page 939: ...8 Rear seat belts sedan 720 9 Front Seat Assembly 720 4 Rear seat belt assembly Sport Wagon 720 9 Front seat belt tensioner Rear seat belts Sport Wagon 720 10 removing and installing 720 4 Front seat...

Page 940: ...essure when red buttonon seat belt loclt is I I Automatic belt soueaks when fastened or I xcessive friction in belt guides IReplace reel assembly Probable cause Accident inwhich bumper impact absorber...

Page 941: ...ing in a collision Seat belts should not be modified or repaired Theseat belt mounting points should not be changed or modi fied Do not bleach or dye seat belt webbing Webbing that is severely faded o...

Page 942: ...replacement work on pyrotechnic devices must be carried out by a quali fied BMW technician Be sure to disconnect the battery and wait 5 seconds before attempting to work on pyrotechnic devices Pyrotec...

Page 943: ...C and slide cover down to remove When reinstalling Replace wire ties to relieve tension on pyrotechnic belt ten sioner harness connector Tightening torques Front seat to floor M10 42 Nm 31 it lb Seat...

Page 944: ...Seat belt lock with pyrotechnic tensioner 9 Tensioner mounting bolt Frontseat belt reel removingand installing sedan and Sport Wagon models Detach battery negative cable in trunk Priorto disconnecting...

Page 945: ...st trim away from post to release clips Slide upper trim panel down arrow to remove Remove automatic reel from B pillar Remove upper seat belt anchor bolt A Remove cross brace mounting bolts B Remove...

Page 946: ...belt to height adjuster 31 Nm 23 it lb Seat belt reel to 3 pillar bottom 31 N m 23 ft lb Sliding height adjuster to 3 pillar 24 N m 18 ft lb Rear seat belt assembly sedan 1 Center shoulder belt reel a...

Page 947: ...allrightlock strap whichis shorter underneathmiddle lock strap Install left lock strap underneathmiddle lap belt strap Metal strap ends must rest against stop on floor under neath seat Rear seat belt...

Page 948: ...shoulder belt reel mounting bolt inside backrest Outboard shoulder belt Remove roof pillar C pillar trim Remove center shoulder belt Lift up rear seat cushion s to access rear seat belt loclc mountin...

Page 949: ...ving and installing 721 9 Airbag indicator light 721 4 Door mountedside impact airbag Warninas 721 5 removinaand installina 721 10 Head protection airbag components 721 11 Airbag Electronics 721 6 Hea...

Page 950: ...e BMW Multiple Restraint System MRS Three versions of MRS are available in E39 models Multiple Restraint Systems MRS and MRS II include the following restraint components 311996 811 997 911997 311 999...

Page 951: ...elfecl when the airbags are lr ggered at lighter impact MRS Ill satellite sensors use 2 wire connectors Rear side airbags arrive de activated from the factory and can only be activated upon written re...

Page 952: ...nologyairbag usedtwo ignition stages Stage one is designed to ignite first during an impact Stage two ignites after a timed period as programmedin the MRS I1control module Airbag indicator light The M...

Page 953: ...work not associat ed with the airbags and before doing any welding on the car 0 After disconnecting the battery wait 5 seconds before beginning work on airbag components If an airbag has been activat...

Page 954: ...MRS airbag system diagram 1 Driver s side airbag 2 Passenger s side airbag 3 Rightside impact sensor 4 Seat occupancy sensor pad 5 Rightside impact airbag 6 SBE control module analog to digital conve...

Page 955: ...nteri or Trim Remove module mounting nuts arrows and lift up control module Disconnect electrical harness connector Installation is reverse of removal Be sure that MRS control module ground cable is a...

Page 956: ...g Disconnect negative cable from battery and cover nega tive terminal with insulatingmaterial WARNING After disconnectingthe batter wait 5secondsbeforebegin ning work on airbagcomponents CAUTION Prior...

Page 957: ...ave been completed start the engine and check that the airbag indicator light goes out If the in dicator light stays on the airbag system will not func tion as designed Have the system diagnosed and r...

Page 958: ...o the ail causino inium Installation is reverse of removal Make sure wiring harness is not pinched when installing airbag unit in dashboard Tightening torques Passengeralr bag to 10 NM 88 in lb dashbo...

Page 959: ...allation is reverse of removal Rear door airbag Detach electrical harness connector Remove mounting bolts and remove airbag from door Installation is reverse of removal Route electrical harnesses as t...

Page 960: ...lar trim Before starting work on the HPS airbag disconnect negative cable from battery and cover negative terminal with insu lating material Prior to disconnectingthe battery readthe battery discon ne...

Page 961: ...e Engineers and CARB CaliforniaAir Resources Board OED I 1isthe second generation of on boardself diagnostic equipmentrequirements These standardswere originally mandatedfor Californiavehicles Since 1...

Page 962: ...s manual three different MIL symbols were used depending on year and model MIL illuminates under the following conditions Engine management system fault detected for two consecutive OED iI drive cycle...

Page 963: ...ive drive cycles without the fault reoccurring A generic scan tool connected to the BMW data link connector DLC or OBD I 1plugcandisplay diagnostictrouble codes DTCs along with the conditions associat...

Page 964: ...airment of the signal or component and determines if a signal or sensor is faulty based on 3 conditions Signal or component shorted to ground Signal or component shorted to B Signal or component missi...

Page 965: ...issions relevant or catalyst damaging Misfiredetection is an on going monitoring process that is only disabled under certain limited conditions Secondary air injection monitoring Secondary air injecti...

Page 966: ...for leaks It can detect very small leaks anywhere in the system A leak detection unit LDPor DMTL is used to pressurize the evaporative control system on a continuous basis as the drive cycle allows an...

Page 967: ...The battery or ECM is disconnected When all zeros are displayed the system has established DTCs are erased after completion of repairs and a drive cycle is not completed readiness Readiness codes can...

Page 968: ...powertrain problem 0 SAE sanctioned or generic a 3 Related to an ignition system misfire 06 Misfire detected at cylinder 6 DTCs provide a freeze frame or snap shot of a vehicle performance or emissio...

Page 969: ...ernal Control Module Memory Check Sum Error Internal Control Module Keep Alive Memory KAM Error ECMIPCM Processor Transmission Range Sensor A Circuit Maliunction PRNDL Input Transmission Range Sensor...

Page 970: ...ct Ratio Gear 5 Incorrect Ratio Gear 5 Incorrect Ratio Torque Converter Clutch Circuitlopen Torque Converter Clutch Circuitlopen Torque Converter Clutch Circuitlopen Torque Converter Clutch Circuit Pe...

Page 971: ...Control Circuit Low Pressure Control Solenoid C Control Circuit High PI734 PI738 Pi738 PO976 117 IShift Solenoid B Control Circuit Low 16 18 62 144 129 51 65 1 PI743 PI743 PI743 PI746 PI746 Pi747 Shif...

Page 972: ...lenoid Open Circuit CAN Throttle Valve CAN Throttle Valve CAN Throttle Valve CAN Torpue Interlace CAN Torque Reduction P I780 I I 108 54 96 2 19 P I780 1163 ICAN Torque Reduction 152 80 81 82 80 16 17...

Page 973: ...c trouble codes M52 engine 5 5 4 4 4 4 I I Pressure Control Solenoid E Control Circuit Low Pressure Control Solenoid E Control Circuit High Torque Converter Clutch Pressure Control Solenoid Control Ci...

Page 974: ...4 PO155 PO156 PO156 PO156 PO150 1154 102 Sensor Circuit Bank 2 Sensor 1 153 PO159 PO161 PO170 0 2 Sensor Circuit Banic 2 Sensor 1 230 187 55 159 160 216 p PO173 PO201 PO202 PO203 PO204 PO205 PO206 0 2...

Page 975: ...Sensor 1 0 2 Sensor Heater Control Circuit Bank 2 Sensor 1 Mass or Volume Air Flow Circuit RangeIPerlormance Problem PI140 I I I P1188 1227 IFuel Control Bank 1 Sensor 1 PI145 150 Solenoid Valve Runni...

Page 976: ...ottle Valve Mechanically Stuck M73 Throttle Valve 1 Spring Test Throttle Valve Mechanically Stuck M73 Throttle Valve 1 Spring Test DlSA Differentiated lntalte Manifold Control Circuit Electrical Map C...

Page 977: ...101 I I POI08 1197 Manifold Absolute PressureIBarometric Pressure Circuit High Input H02S Heater Control Circuit High Bank 2 Sensor 1 H02S Heater Control Circuit Bank 2 Sensor 2 HO2S Heater Control Ci...

Page 978: ...113 Injector CircuiVOpen Cylinder 2 Injector CircuiVOpen Cylinder 3 lnjeclor CircuiVOpen Cylinder 4 Injector CircuiVOpen Cylinder 5 Injector CircuiVOpen Cylinder 6 ThrotileiPedal Position SensorISwiic...

Page 979: ...Misfire Detected PO313 PO306 1 243 I Cylinder 6 Misfire Detected 242 PO313 PO313 PO313 PO327 Cylinder 5 Misfire Detected PO313 1239 I Misfire Detected with Low Fuel 238 PO332 PO335 PO339 PO340 Misfir...

Page 980: ...Bank 1 Sensor 1 Fuel Control Limit Mixture Too Lean Bank 2 Sensor 1 Fuel Control Limit Mixture Too Rich Banic2 Sensor 1 229 229 230 235 PI121 PI122 PI123 0 2 Sensor Circuit Slow Response in Lean Cont...

Page 981: ...e Sensor Variant Recognition Learning Failed Pre Catalyst Fuel Trim System Bank 1 Pre Catalyst Fuel Trim System Bank 2 PI139 PI143 PI144 PI149 PI150 PI151 PI152 PI153 PI155 P1156 PI157 PI171 PI172 PI1...

Page 982: ...it Signal High Diagnostic Module Tank Leakage DM TL Pump Control Open Circuit Diagnostic Module Tank Leaitage DM TL Pump Control Circuit Signal Low Diagnostic Module Tank Lealtage DM TL Pump Control C...

Page 983: ...tion Spring Test Failed Throttle Valve Adaptation Lower Mechanical Stop not Adapted Throttle Valve Control Circuit Throttle Valve Position Control Control Deviation P I637 I I P2270 1215 1 0 2 Sensor...

Page 984: ...er Control Circuit Banlc2 Sensor 1 H02S Heater Control Circuit Low Bank 2 Sensor 1 H02S Heater Control Circuit High Bank 2 Sensor 1 H02S Heater Control Circuit Bank 2 Sensor 2 HO2S Heater Control Circ...

Page 985: ...8 5 20 20 20 PO161 PO171 PO171 PO172 PO172 PO174 PO174 I I PO201 1150 I Injector CircuiVOpen Cylinder 1 0 2 Sensor Circuit High Voltage Bank 2 Sensor 1 0 2 Sensor Circuit Slow Response Bank 2 Sensor 1...

Page 986: ...On Board Diagnostics...

Page 987: ...Air Mass Too Low Secondary Air Injection System Switching Valve A Circuit Open Secondary Air Injection System Control A Circuit Catalyst System Efficiency Below Threshold Bank 1 Catalyst System Effici...

Page 988: ...nk 2 Sensor 2 0 2 Sensor Heater Circuit High Voltage Bank 2 Sensor 2 Fuel Trim Adaptation Additive Low Bank 1 Fuel Trim Ada tation Additive Hish Banlc 1 P I328 P I332 P I333 P I340 PI341 PI342 PI343 I...

Page 989: ...ontrol Circuit Signal High Diagnostic Module Tank Leakage DM TL Pump Current Too High during Switching Solenoid Test Diagnostic Module Tank Leakage DM TL Pump Current Too Low Diagnostic Module Tank Le...

Page 990: ...1 P2192 P2193 P2194 P2270 A Camshaft Position Actuator Control Circuit High Bank 2 Post Catalyst Fuel Trim System Too Lean Bank 1 Post Catalyst Fuel Trim System Too Lean Bank 2 System Too Lean Off Idl...

Page 991: ...2 Airbag system SRS 2 stage airbag 721 4 control module replacing721 7 driver airbag removinglinstalling 721 8 iiead protectionairbag 721 12 components 721 11 indicatorlighl721 4 passengerairbag remov...

Page 992: ...troubleshooting 340 5 Bulbs see Lights Bumper lront 510 6 height adjusting510 12 rear 510 9 Bus system 600 4 Camber 320 33 Camshaft removingiinslaiiing M52 engine 116 12 M52TU M54 engine 116 19 M62 e...

Page 993: ...enance therrnostat 170 16 transmission fluid heat exchanger 170 5 troubleshooting 170 7 combuslion leal test 170 10 pressure test 170 9 Crankshaft oil seals iront 117 6 rear 119 6 Crankshaft speed sen...

Page 994: ...600 12 wiring diagrams 600 12 Electrical wiring diagrams ELE 1 Eiectricaliy heated thermostat characteristic map 170 4 Eiectronic height control EHC 300 8 330 44 Eiectronic immobilization see EWS ele...

Page 995: ...ex disc see Driveshaft Fluids and lubricants see Maintenance Flywheel removinglinstalling210 13 Fogllght see Lights Front centering guide see Driveshatt Front oil seal see Crankshaftoil seals Front su...

Page 996: ...ture sensor see 130 under appropriatefuel injection system idle speed control valve see 130 under appropriatefuel injection system Idle stabilizer see 130 under appropriatefuel injection system idie s...

Page 997: ...V Elower 119 13 V 8 upper 119 15 oil pressure checiring 119 4 warning system testing 119 5 warning switch replacing 119 20 oil pressure relielvalve 6 cylinder 119 26 V 8 119 27 oil pump removinglinsta...

Page 998: ...see Lubricationsystem Oil pump see Lubricationsystem Oil service 020 11 On Board Monitor 640 12 On board diagnostics OED 1 Outside air temperature sensor 610 14 Outside door handle see Door loclc Out...

Page 999: ...see Rear suspension Ring antenna see EWS electronic immobilizalion Rotor see Brakes Roundel see Exteriortrim Running tosses 312 way valve see Fuel tenlr SCA soft close seeTailgate soft close see also...

Page 1000: ...ual transmission 230 8 automatic transmission see Automatic transmission range switch center console switches 612 11 central ioci ing 612 11 hazard 612 1I headlight 612 9 ignition cylinder320 11 612 6...

Page 1001: ...Manual transmission oil seals Trim interior see interior trim see also Steering steering column trim Trunk lid 412 2 soft close SCA 515 13 see also Trunkltailgale loci see also Centraliocl ing TrunWt...

Page 1002: ...w Window regulator see Door window Window switch 512 3 see Switches Windows door see Door window Windshield wipers and washers see Wipers and washers see also Maintenance Wiper motor see Wipers and wa...

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